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 . . . . . . . . . . .51
Appendix N: Reliability Package . . . . . . . . . . . . . 52

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Owners Manual • Falk® Quadrive® Shaft Mounted Drives Model A
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INTRODUCTION DRIVE RATING — Operate the drive only within the

horsepower and output speed for which it was selected
WARRANTY — Rexnord Industries (the “Company”)
and specified in Selection Guide 371-110 for the
warrants that, for a period of three years from the
application. Refer to the nameplate for drive size, ratio and
date of shipment, the product described herein will
data.
deliver successfully its rated output as indicated on
the nameplate, provided it is properly installed and FALK FACTORY REPAIR AND REBUILD — Rexnord wants
maintained, correctly lubricated, and operated in the to continue to be your primary supplier, and we extend our
environment and within the limits of speed, torque or other service to you if your equipment is in need of repair or
load conditions for which it was sold. Such product is replacement.
expressly not warranted against failure or unsatisfactory We are able to furnish a fast turnaround on both the
operation resulting from dynamic vibrations imposed quotation and rebuild. Nobody can do the job better than
upon it by the drive system in which it is installed, unless Rexnord. If you need repair on Rexnord products,
the nature of such vibrations has been fully defined just ask.
and expressly accepted in writing by the Company as a Contact your local Rexnord Account Executive or distributor
condition of operation. for more information.
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.

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 Falk® Quadrive® Shaft Mounted Drives Model A • Owners Manual
Sizes 5107-5315 (Page 3 of 52)

Drive Identification
5 107 J 25 A

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

+ Electric Fans
1) Basic Drive (5307 & 5315 only)
TA Taper Bushing Optional

+ 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).

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Section I
DRIVE INSTALLATION
OUTFITTING 2. JR — Remove anchor brackets, housing flange fasteners
and rod end fasteners from tie rod kit and assemble
1. JR, JF, & JSC — Find the desired mounting position
to drive as illustrated in Figure 2. Refer to Table 1 for
in Figure 1 and install air vent and magnetic drain plug
tightening torque (original fasteners may be discarded).
(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 Figure 2 HOUSING FLANGE
FASTENERS
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.
ANCHOR ALTERNATE
Figure 1 HORIZONTAL DRIVES BRACKET LOCATION
TORQUE ARM PREFERRED
F REPOSITION PLUGS TO
510 7 & 5115 FASTENER 5203 THRU 5315 LOCATION
SUIT REQ’D MOUNTING
SIZES 5203 THRU 5315
L
5:1 RATIO ONLY: RELOCATE D = DRAIN
AIRVENT ON OUTPUT SIDE F = Fill & Vent
L = OIL LEVEL
TABLE 1 — Housing Flange Fastener Size
FOR 9 O’CLOCK MOUNTING
(HIGHEST INPUT and Tightening Torque
SIDE PLUG) (Non-Lubricated Fasteners)
F D F
12 O’ CLOCK Tightening Torque lb-ft
DRIVE SIZE Fastener Size (Nm)
L L
5107 .312-18 19 (26)
5115 .312-18 19 (26)
5203 .375-16 28 (37)
D F D 5207 .500-13 69 (94)
9 O ’CLOCK 3 O ’CLOCK 5215 .500-13 69 (94)
5307 .500-13 69 (94)
L 5315 .500-13 69 (94)

3. JR — The tapered bore hollow shaft is designed for use

D with a TA Taper bushing for mounting on a driven shaft with
6 O ’CLOCK 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
VERTICAL DRIVES shown in Table 2. The minimum engagement is necessary
for full bushing engagement; the maximum engagement is
STANDPIPE & FILL VENT & only required if a thrust plate will be employed to remove the
VENTED DIPSTICK STANDPIPE drive from the driven shaft (see Appendix C for preferred
FILL OIL LEVEL removal method).
± 1° MAX

TABLE 1A — Driven Shaft Tolerances 

Shaft Diameter – Inches Maximum Under-size – Inches
DRAIN DRAIN Up to 1.500 .004
INPUT SHAFT DOWN INPUT SHAFT UP 1.500 - 2.500 incl. .005
2.500 - 4.000 incl. .006

ANGULAR LIMITS FOR HORIZONTAL MOUNTING c Millimeters = h10 tolerance.

(ALL CLOCK POSITIONS) Figure 3
THRUST N
MINIMUM SPACE REQUIRED
PLATE
HOLLOW DRIVEN
INCLINE ROTATION
SHAFT SHAFT
COVER BUSHING
30 ° UP NUT
(20° FOR HIGH-SPEED
5315) SHAFT BEARING
SUPPORT
SHEAVE
MINIMUM SPACE REQUIRED
FOR V-BELT CLEARANCE
5 ° DOWN
5° 10° TORQUE
10 ° 5°
0° Incline down on drives MAX MAX MAX MAX ARM
with backstop in 9 or 12
o’clock mounting position. (5107 & 5115) (5203 THRU 5315) CLEVIS
BRACKET

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 Falk® Quadrive® Shaft Mounted Drives Model A • Owners Manual
Sizes 5107-5315 (Page 5 of 52)

4107 and will employ a 2.437” (61.9 mm) or 3.000”

TABLE 2 — N Dimension Inches (mm)  (76.2 mm) diameter drive shaft, place the (2) gaskets
DRIVE SIZE Minimum Maximum and trough end spacer, packaged separately, over
the trough end surface of the seal housing, Figure 6.
5107 5.00 (127) 7.19 (183)
5115 5.55 (141) 8.05 (204) Continue outfitting based on the type of trough end
5203 5.53 (140) 7.78 (198) seal to be installed: (a) Waste Packing Seal; (b) Lip
Seal or; (c) Packing Gland Seal.
5207 6.11 (155) 8.72 (221)
5215 7.08 (180) 10.15 (258)
5307 7.39 (188) 10.69 (272) Figure 5
HOLLOW
5315 7.92 (201) 10.74 (273)
SHAFT
c 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 RETAINING
shaft. OUTPUT
RING
a. THIN WALL BUSHING (with keyway slot through SIDE
THRUST
the bushing wall) — With the driven shaft keyway PLATE
at the 12 o’clock position, slide bushing assembly
onto the driven shaft, nut end first, and position
the keyway slot over the shaft keyway (the bushing
may have to be pried open slightly). Insert the
drive, key furnished with the bushing, into the
shaft keyway. Proceed to Step 7. Figure 6

DRIVE SHAFT

MECHANICAL LIP SEAL

DRIVESHAFT THROUGH END SPACER

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

b. THICK WALL BUSHING (with separate internal GASKET

and external keyways) — Insert the driven shaft TROUGH END
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 a. WASTE PACKING SEAL (Figure 7) — Slide drive
the shaft key under operating conditions. Slide shaft thru seal housing. Insert key into drive shaft and
the bushing assembly onto the driven shaft (the slide drive shaft into hollow shaft. The seal housing
bushing may have to be pried open slightly). registers into the basic drive seal bore. Install the drive
Rotate the shaft so the external keyway in the shaft thrust plate fastener thru thrust plate and torque
bushing is at the 12 o’clock position. Then insert to the value specified in Table 3. Use the seal housing
the drive key, furnished with the bushing, into fasteners to secure the seal housing to the basic drive
the keyway. Proceed to Step 7. housing. Refer to Table 4 for proper torque value.
Reinstall hollow shaft cover. Pack seal housing with
waste packing and proceed to Step 5.
Figure 4
TABLE 3 — JR & JSC Thrust Plate Fastener
Data (Non-Lubricated Fasteners)
Min Thread
DRIVE Fastener Size Torque Depth Inches
SIZE & Grade  lb-ft (Nm) (mm)
5107 .500-13UNC x 3.25, GR. 8 92 (125) 2.00 (50.8)
5115 .500-13UNC x 3.25, GR. 8 92 (125) 2.00 (50.8)
5203 .625-11UNC x 3.50, GR. 8 183 (248) 2.00 (50.8)
4. JSC — NOTE: See Appendix K for non-tapered 5207 .625-11UNC x 3.50, GR. 8 183 (248) 2.00 (50.8)
drive shafts. Remove the hollow shaft cover 5215 .875-9UNC x 3.50, GR. 8 533 (723) 2.50 (63.5)
from the input side of the hollow shaft bore and 5307 1.00-8UNC x 4.00. GR. 5  567 (769) 2.75 (69.8)
5315 1.00-8UNC x 4.00. GR. 8 792 (1074) 2.75 (69.8)
save. Separate contents from the drive shaft
kit. Install thrust plate and retaining ring in the c Fastener lengths given are for applications using tapered drive shafts.
Other lengths may be needed for applications using tapered bushings.
hollow shaft, Figure 5. When the drive is a size „ 1.00-8UNC x 3.50, GR. 5 for 5307JF.

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Figure 7

SEAL HOUSING FASTENERS

TROUGH END GASKET WITH LOCK WASHERS
TROUGH END SEAL HOUSING
BASIC DRIVE
TROUGH END DRIVE SHAFT KEY
MOUNTING FASTENERS

HOLLOW SHAFT COVER

THRUST PLATE
RETAINING RING
WASTE PACKING
THRUST PLATE
DRIVE SHAFT THRUST
DRIVE SHAFT INSERT PLATE FASTENER

b. LIP SEAL (Figure 8) — Coat outside diameter of

TABLE 4 — Seal Housing & Trough End seal with Permatex #3 or equivalent. Drive seal into
Fastener Size – UNC & Tightening seal housing with the spring-loaded seal lip away
Torque (Non-Lubricated Fasteners) from the driver. Wrap the keyway on tapered shank
DRIVE SIZE of drive shaft with masking tape or lightweight Kraft
Fastener
Location paper to protect against damaging the seal lips.
5107 5115 5203 5207 5215 5307 5315
Coat the seal lips and straight portion of the drive
Seal Housing .500-13 .625-11 .750-10 .875-9 1.000-8 1.000-8 1.000-8 shaft with bearing grease. Line up the keyway in
Fasteners 69 (94) 137 (186) 245 (332) 380 (515) 567 (769) 792 (1074) 792 (1074)
lb-ft (Nm) the drive shaft with the hollow shaft keyway and
insert the drive shaft into the seal housing. Remove
1.500” Diameter Drive Shaft the protective wrap and install the drive shaft key.
.500-13 Fasteners
69 (94) Insert the drive shaft into the hollow shaft. The seal
Trough End
Fasteners housing registers into the basic drive seal bore.
2.000” & 2.437” Diameter Drive Shafts Use the thrust plate fastener, Figure 7, to secure the
lb-ft (Nm) .625-11 Fasteners with Nuts — 137 (186)
drive shaft. Refer to Table 3 for proper torque value.
3.000” & 3.437” Diameter Drive Shafts Install the seal housing fasteners to secure the
.750-10 Fasteners with Nuts — 245 (332)
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 PACKING GLAND RING
AFTER CUTTING
(TWO REQUIRED)
TROUGH END GASKET CUT
TROUGH END SEAL HOUSING
TROUGH END SHAFT
MOUNTING FASTENERS
BUTT JOINT
PACKING GLAND ROPE

Figure 10
DRIVE SHAFT INSERT PACKING GLAND (TWO RINGS)
DRIVE SHAFT INSERT

TROUGH END
MECHANICAL LIP SEAL
TROUGH END SPACER
TROUGH END GASKETS (SIZE 5107 WITH 2.437” & COMPRESSION RING
(SIZE 5107 WITH 2.437” & 3.000” DRIVE SHAFTS ONLY) FASTENER WITH
3.000” DRIVE SHAFTS ONLY) COMPRESSION RING 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 shaft’s seal surface.

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Remove packing rings from the drive shaft and slide Figure 11
the drive shaft through the seal housing. Install seal SLING FROM SLING AROUND
LONG FASTENER SEAL HOUSING
rings into the seal housing. Stagger the seal joints WITH NUT AND INPUT SHAFT
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 SLING FROM
EYEBOLTS
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 8. JR — If the drive was received with a backstop
drive to the driven shaft is to prepare the driven shaft installed, the backstop must be temporarily removed to
per Appendix H and mount the drive to the tapered facilitate mounting.
shaft using a thrust plate kit with fastener as shown in Refer to Section II, Figure 19 and remove cover Ref.
Table 3. An optional method of connection should be #16 and backstop Ref. #5A1.
used when replacing existing drives with special shafts
or when producing tapered shafts is impractical. 9. JR — Lift the drive into position and slide onto the
This optional method uses a TA tapered bushing as drive shaft taking care that the driven shaft key seats
outlined in Appendix J. 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
TABLE 5 — Flange-Mounted Drive – Foundation vary within the range shown. For torque arm mountings
Fastener Size & Tightening other than shown, refer to Rexnord. If it is necessary
Torque (Non-Lubricated Fasteners) to shorten the torque arm, cut the excess from either
threaded end.
Min Fastener
Torque Engagement The support to which the clevis bracket is to be
DRIVE fastened must sustain the torque reaction shown
Fastener Size and Grade lb-ft Into Drive
SIZE (Nm) Housing in Table 8. The maximum load reaction through the
Inches (mm) torque arm occurs when the torque arm is located
5107 .500-13UNC, GR.5 69 (94) .76 (19.3) in the extreme (30°) off angle position. Use Grade 5
5115 .625-11UNC, GR.5 137 (186) .94 (23.9) fasteners to anchor the clevis bracket; see Table 7 for
5203 .750-10UNC, GR.5 245 (332) .76 (19.3) the fastener diameter and tightening torque.
5207 .875-9UNC, GR.5 380 (515) .88 (22.4) Bolt the tie rod to both the clevis bracket and the
5215 1.000-8UNC, GR.5 567 (769) 1.00 (25.4)
5307 1.000-8UNC, GR.8 792 (1074) 1.24 (31.5) drive anchor bracket and tighten the bolts until seated
5315 1.000-8UNC, GR.8 792 (1074) 1.24 (31.5) against the brackets. DO NOT bend the bracket as
clearance between the clevis brackets and tie rod is
necessary.
INSTALLATION
7. JR, JF, & JSC — Refer to Figure 11 for recommended lifting
method. In order to sling JR & JF as illustrated, remove
a housing flange fastener and install a long fastener with
nut. For vertical installation, use (3) eye bolts as illustrated.
Eyebolt sizes are 5/16” for 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.

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Figure 12 TABLE 8 — Load Reaction Through Torque Arm

HIGH- HOUSING FLANGE
FASTENERS
SPEED DRIVE
SHAFT 5107 5115 5203 5207 5215 5307 5315
SIZE
TORQUE ARM
FASTENER Load 2440 3810 4680 6750 9160 12963 15890
2° 2°
lb (N)  (10850) (16940) (20810) (27790) (40720) (57660) (70700)

X 30 c Load includes moment due to motor and motor mount with torque arm at
MA °M maximum angle.
30° AX
ANCHOR BRACKET CLEVIS
BRACKET
10. JR — Thread the bushing nut onto the hollow shaft
5107 & 5115 one to two turns. NOTE: The bushing nut threads
have been coated with an anti-seize compound at
HIGH- the Factory. This compound should not be removed.
SPEED
SHAFT 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,
ANCHOR
BRACKET
2° additional anti-seize compound MUST be applied to
TORQUE ARM 30°
the threads of the TA bushing nut.
FASTENER MA
5203 THRU 5315
X
CLEVIS
WARNING: DO NOT apply anti-seize or lubricant to bushing or
PREFERRED MOUNTING BRACKET shaft surfaces. Use of anti-seize may prevent secure connection
of the drive to the shaft and cause the drive to move.
DO NOT apply ANTI-SEIZE
HIGH-
SPEED on these areas.
SHAFT

2° ANCHOR
BRACKET
TORQUE ARM
AX FASTENER
°M
30
CLEVIS 5203 THRU 5315
BRACKET ALTERNATE MOUNTING
WARNING: Overtightening can fail the internal retaining
TABLE 6 — Spanner Wrench Type & ring (see Appendix G, for listing of retaining rings).
Spanner Nut Tightening Torque a. PREFERRED METHOD — Use a spanner (Table 6),
chain or pipe wrench to tighten the bushing nut to
Adjustable Hook Spanner Wrench Spanner Nut
DRIVE Tightening Torque the torque value indicated in Table 6. Apply Loctite
SIZE GearWrench Williams 243 or equivalent to threads of setscrew. Tighten
lb-ft (Nm)
the setscrew on the bushing nut to torque value
5107 81856 (2" to 4-3/4") 474 83 (113) indicated in Table 6A.
5115 81856 (2" to 4-3/4") 474 83 (113)
5203 81856 (2" to 4-3/4") 474 167 (226) b. ALTERNATE METHOD — (To be used when torque
5207 81857 (4-1/2" to 6-1/4") 474A 167 (226) cannot be measured.) Use a spanner (Table 6),
5215 81857 (4-1/2" to 6-1/4") 474A 250 (339) chain or pipe wrench to tighten the bushing nut
5307 81857 (4-1/2" to 6-1/4") 474A 250 (339) just until the drive can no longer be moved by hand
5315 81858 (6-1/8" to 8-3/4") 474B 250 (339) 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
TABLE 6A — Bushing Nut Setscrew – the top of the driven shaft. Next mark a spot on
Tightening Torque the bushing nut 180° from the driven shaft mark
DRIVE SIZE Setscrew Size Tightening Torque lb-ft (Nm) (90°CCW for sizes 5107 & 5115). Use the spanner
wrench to tighten the nut CW one half turn until the
5107 .250-20 5 (7) two marks are aligned (one quarter turn for sizes
5115-5207 .312-18 11 (15)
5215-5315 .375-16 19 (26) 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.
TABLE 7 — Torque Arm Clevis Bracket 11. JR — Install backstop, motor mount, motor, sheaves
Fastener Tightening Torque (mount sheaves as close to the drive and motor housing
DRIVE Fastener  Tightening Torque – lb-ft (Nm) as possible), belts and guard. Refer to Appendix D for
SIZE Size motor mount installation instructions. Proceed to Step 14.
Steel Foundation Concrete Foundation
5107 .375-16UNC 28 (38) 21 (28)
12. JF (USING TAPERED DRIVE SHAFT) — Put key into
5115 .375-16UNC 28 (38) 21 (28) the driven shaft. Lift drive into position and slide onto
5203 .500-13UNC 69 (94) 53 (72) the driven shaft taking care that the driven shaft key
5207 .500-13UNC 69 (94) 53 (72) seats into the hollow shaft keyway. DO NOT hammer
5215 .625-11UNC 137 (186) 107 (145) or use excessive force. Secure the drive to the shaft
5307 .750-10UNC 245 (332) 191 (259) with the thrust plate fastener. Refer to Table 3 for
5315 1.000-8UNC 567 (769) 467 (633) torque value. Reinstall the hollow shaft cover. Install
c Grade 5 fasteners required. motor mount, motor, sheaves, belts and guard. Refer
to Appendix D for motor mount installation instructions.
Proceed to Step 15.

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13. JSC — Assemble drive to trough and install drive shaft Coat the plug threads with #3 Permatex or equivalent
coupling bolts per screw conveyor manufacturer’s thread sealant before replacing.
instructions. Install motor mount, motor, sheaves, belts 17. JR, JF, & JSC — Where applicable, pump grease into
and guard. Refer to Appendix D for motor mount the high-speed shaft seal cover with a Hand Grease
installation instructions. Proceed to Step 15. Gun, Figure 14, until fresh grease flows out along the
14. JR — When the torque arm turnbuckle is used for shaft. Wipe off excess grease from the shaft. DO NOT
belt tension adjustment, position the motor so that the use grease where it could contaminate the product,
belt pull will be about 90° to a line through the drive e.g. foods, drugs, etc.
high-speed shaft and hollow shaft as shown in Figure
13. For drives where the motor is moved to adjust belt
Figure 14
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. HIGH-SPEED SHAFT

Figure 13

START UP
18. JR, JF, & JSC — Before operating the drive, check any
fasteners, pipe plugs, air vent, etc. which may have
been loosened in the course of outfitting, installing
and lubricating the drive to be sure that they have
been properly retightened. If a long fastener was
BELT TENSION ADJUSTED
used to lift the drive into place, reinstall the housing
WITH TORQUE ARM
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
PARALLEL same type and viscosity grade as the original
charge (warmed to approximately 100°F (38°C) in
cold weather). Rapidly pour or pump a charge
equal to 25-100% of the initial fill thru the drive, or
BELT TENSION ADJUSTED until clean oil flows thru the drain.
WITH MOVABLE MOTOR 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 TABLE 9 — Approximate Oil Capacity –
lubricant. Refer to Table 9 at right for approximate oil Quarts (Liters) 
capacity of drives. DRIVE SIZE JR, JF, & JSC JRV & JFV
16. JR, JF, & JSC — HORIZONTAL MOUNTING
5107 2 (1.9) 3 (2.8)
Remove air vent and oil level plug (refer to Step 1). Fill 5115 3 (2.8) 4.5 (4.3)
the drive until oil shows in the oil level hole. Coat the air 5203 3.5 (3.3) 5 (4.7)
vent and plug threads with #3 Permatex or equivalent 5207 5.5 (5.2) 7.5 (7.1)
thread sealant before replacing. 5215 9 (8.5) 13 (12.3)
5307 13 (12.3) 18 (17)
JRV, JFV, & JSCV — (VERTICAL MOUNTING) Refer 5315 15 (14.2) 21 (19.9)
to Figure 1, Step 1.
c Quantities are approximate. Always fill drive to specified level.
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.

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Owners Manual • Falk® Quadrive® Shaft Mounted Drives Model A
(Page 10 of 52) Sizes 5107-5315

Section II
DRIVE SERVICE & REPAIR
PREVENTIVE MAINTENANCE
Periodically inspect stored or inactive gear drives and
PERIODICALLY — Carefully check the oil level of the drive add Nox-Rust VCI-10 every six months, or more often if
when it is stopped and at ambient temperature; add oil if necessary. Indoor dry storage is recommended.
needed. If the oil level is above the specified level, have
the oil analyzed for water content. Moisture in the oil may The air breather should be replaced with a plug (air
indicate seal leakage or condensation. If so, correct the breather should be attached to gear drive for future use)
defect immediately and change the oil. DO NOT overfill or so that the protective rust inhibiting atmosphere is sealed
oil leakage may result. If a drive is equipped with a fan, inside the drive. Install air breather when preparing drive
periodically clean accumulated foreign matter from the fan for operation.
and fan guard to allow adequate air flow. WARNING: The rust preventative oil from the factory
GREASE PURGED SEALS — Periodically (at least every and Nox-Rust VCI-10 are not H1 registered with the NSF
six months), depending upon the frequency and degree (National Sanitation Foundation) as suitable for food
of contamination, purge contaminated grease from seal processing applications. When Food Grade Lubricants are
by slowly pumping fresh bearing grease through the seal to be used, it is the end users responsibility to properly
cage, WITH A HAND GREASE GUN, until fresh grease flush and prepare the drive for Food Grade service.
flows out along the shaft. Wipe off the purged grease. Contact the lubricant manufacturer for specific information
Refer to Appendix A. and flushing procedures.
PACKING GLAND SEAL — Section I, Step 4(C)
REPAIR & REPLACEMENT
OIL CHANGES WARNING: Consult applicable local and national safety
codes for proper guarding of rotating members. Lock out
Refer to the Lubrication Recommendations Section in power source and remove all external loads from drive
Appendix A. before servicing drive or accessories.
NOTE: Only the seals on the input side of the drive can
STORED & INACTIVE GEAR DRIVES be replaced without removing the drive from the driven
equipment. All other repairs require removal of the drive
Each drive is protected with a rust preventive that will
from the driven equipment. Proceed to Step 1 for drive
protect parts against rust for a period of 4 months in
removal. Proceed to Step 5 for replacement of seals.
an outdoor shelter or 12 months in a dry building after
shipment from the Factory. Removal (See above note for seal replacement only)
If a gear drive is to be stored, or is inactive after installation 1. JR, JF & JSC — Drain the lubricant at this time.
beyond the above periods, add Nox-Rust VCI-10  vapor- Remove safety guards and belts (motor and motor
phase rust inhibitor. For drives that have oil installed, add mount, optional). Remove backstop (if so equipped).
Nox-Rust VCI-10 vaper-phase rust inhibitor at the rate of Refer to Section II, Step 10, for backstop removal
2% of sump capacity. For drives without oil, add Nox-Rust instructions.
VCI-10 vapor-phase rust inhibitor at the rate of one ounce WARNING: Drive must be supported during removal
per cubic foot of internal drive space. Rotate the shafts process. Use a sling around the motor mount or as
several times by hand. Before operating, drives which have recommended in Section I, Step 7. Take up the slack in the
been stored or inactive must be filled to the proper level sling before proceeding.
with oil meeting the specifications given in this manual.
Refer to Manual 128-014 for "Start-up after Storage"
instructions.
c Product of the Daubert Chemical Company, Chicago, Illinois.

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 Falk® Quadrive® Shaft Mounted Drives Model A • Owners Manual
Sizes 5107-5315 (Page 11 of 52)

2. JR — Refer to Appendix C for instructions on using the Figure 15 TAPPED HOLE

TA Torque Assist Removal Tool. BACKING BOLT IN DRIVE SHAFT
Alternate Method — Loosen the setscrew on the REMOVAL
bushing nut, which is located at the output end of the BOLT
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 THRUST
drive for lifting by disconnecting the torque arm at PLATE
the drive end. Slide the drive from the bushing. The
bushing can be left in place or removed, as required. RETAINING
RING
If bushing will not slide off of the shaft, insert a small DRIVE SHAFT
pry bar into the split of the bushing and pry the split HOLLOW
open slightly to loosen the bushing and remove from SHAFT
the shaft. Proceed to Step 5 for replacement of seals FLAT WASHER
or Step 9 for drive disassembly procedure.
3. JF & JSC — Remove the cover from the input end of
the hollow shaft. CAUTION: Failure to follow this procedure may result
in the destruction of the threads in the thrust plate
JF — Remove the bolts which fasten the drive to the (if the retaining ring becomes damaged, refer to
driven equipment. Appendix G, for replacement information).
JSC — (a) If the drive is to be removed from the drive Proceed as follows:
shaft, remove the seal housing fasteners (Figure 7,
Section I), or (b) if the drive is to be removed with the JF to Step 5 for replacement of Quadrive seals only OR
drive shaft attached, remove the trough end mounting Step 9 for drive disassembly procedure.
fasteners and drive shaft coupling bolts. Remove the 4. JSC — If the drive was removed with the seal housing
assembly from the trough. and the drive shaft attached, remove the seal housing
JF & JSC — Remove the thrust plate, fastener and fasteners to separate the seal housing and drive
retaining ring from the hollow shaft. Refer to Table 10 shaft from the drive. After separation of the drive and
and select a backing bolt and flat washer and install shaft has been achieved, determine the type of seal
them into the drive shaft as illustrated in Figure 15. The equipped in the seal housing. If it is a waste packing
head of the backing bolt provides a working surface seal (Figure 7, Section I), a packing gland seal
for the removal bolt. Reinsert the thrust plate and (Figure 10, Section I) or a lip seal (Figure 8, Section I),
retaining ring into the hollow shaft and select a removal proceed as follows for removal of the drive shaft from
bolt from Table 10. Thread the removal bolt into the the seal housing:
thrust plate until it contacts the backing bolt head. a. PACKING GLAND SEAL — Remove the key from
Torque the removal bolt to the value shown in Table the drive shaft keyway. Loosen the compression
10 (if the thrust plate rotates in the shaft, align the slot ring fasteners. Remove the seal housing toward the
in the plate with the hollow shaft keyway and insert a tapered end of the drive shaft.
screwdriver or piece of key stock to prevent rotation of b. LIP SEAL — Remove the key from the drive shaft
the plate). After torquing the bolt as instructed, strike keyway. Remove any burrs from the tapered end
the bolt sharply with a hammer and re-torque the bolt of the shaft and wrap the entire length with masking
if separation of the drive from the shaft did not occur. tape or a lightweight Kraft paper to protect the
Repeat this procedure, re-torquing the bolt after each seal lips during removal. Carefully remove the seal
blow, until separation occurs. housing toward the tapered end of the drive shaft.
For replacement of Quadrive seals only proceed to
Step 5, otherwise to Step 9.
TABLE 10 — Removal & Backing Bolt Size &
c. WASTE PACKING SEAL — Remove the key from
Length the drive shaft keyway. Remove the waste packing
Maximum material and remove the seal housing toward the
Removal Bolt Backing Bolt
Tightening tapered end of the drive shaft.
DRIVE SIZE Size & Minimum Size & Maximum
Torque
Length - Inches Length - Inches
lb-ft (Nm)
5107 0.625-11UNC x 1.75 133 (180) 0.500-13UNC x 1.25
5115 0.625-11UNC x 1.75 133 (180) 0.500-13UNC x 1.25
5203 0.750-10UNC x 2.00 242 (328) 0.625-11UNC x 1.75
5207 0.750-10UNC x 2.00 242 (328) 0.625-11UNC x 1.75
5215 1.000-8UNC x 2.50 567 (769) 0.875-9UNC x 2.25
5307 1.125-7UNC x 3.00 742 (1006) 1.000-8UNC x 2.50
5315 1.125-7UNC x 3.00 742 (1006) 1.000-8UNC x 2.50

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(Page 12 of 52) Sizes 5107-5315

DRIVE DISASSEMBLY — (Refer to Parts Drawing Figure 17

Figure 19) RIGHT WAY
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 WRONG WAY
driven shaft. Remove input side seal covers, Ref. #13 &
15, as illustrated in Figure 16.

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 6. SEAL SURFACE CONDITION — Carefully inspect
shaft. polished surface of shaft where the seal makes
c. Insert two #10-.750” (M5 x 20) sheet metal screws contact. If the seal surface shows any sign of a nick,
into the seal case leaving .5” (13 mm) of the screw scratch, spiral swirl or groove, the shaft should be
protruding above the seal face. DO NOT drive the replaced or refurbished to prevent leakage of the
screw more than .25” (6 mm) beyond seal face or lubricant. (In many instances, the seal surface can be
bearing damage may occur. Use a claw type pry restored by use of a thin wall wear sleeve. Check with
bar under the screw head as shown in Figure 17 to your local seal supplier and follow the manufacturer’s
lift seal out. Remove all metal chips. Use a magnet instructions for installing the wear sleeve.)
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.

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Sizes 5107-5315 (Page 13 of 52)

7. SEAL INSTALLATION CAUTION: On sizes 5203 thru 5315, tapered roller

CAUTION: Protect seal lips from sharp edges of bearing cups are assembled in input housing with
the keyway by wrapping thin, strong paper around a slight clearance fit. In addition, metal shims for
the shaft and coating the paper and seal lips with adjusting bearing preload and axial float are installed
grease before sliding the seal on or off the shaft. Do behind bearing cups in housing. When handling input
not expand the seal lips more than .030” (0.75 mm) housing, be careful that bearing cups and shims do
diameter. not fall out of input housing.
a. Coat O.D. of seal with #3 Permatex or equivalent 14. If drive is equipped with a backstop, check the shaft
sealant. Position seal squarely in seal bore with surface and backstop sprags (inside diameter) for
the garter spring toward bearing. Place a square signs of wear. If either component shows evidence
ended cylindrical tool against seal and press or of wear, both should be replaced (Ref. #1A and 5A or
lightly tap tool (not seal) until seal outer wall is Ref. #3A and 5A assemblies). Also refer to Step 6 for
seated .14” (3.5 mm) inside the seal bore outer inspection of seal surfaces.
wall. 15. Inspect gear teeth for wear or indications of fatigue
CAUTION: A shaft shoulder is NOT provided for e.g. hairline cracks at root of tooth. If one element has
stopping seal. DO NOT seat seal against bearing. undergone severe wear or broken teeth, replace the
mating element also.
b. Measure seal axial run-out with a dial indicator
mounted on the shaft. If the seal axial run-out is 16. Clean and inspect bearings for wear. Lubricate with
more than .010” (0.25 mm), tap high side of seal light oil before spinning to avoid scoring of working
with installation tool until seal axial run-out is .010” surfaces. Remove any worn bearings with a wheel
(0.25 mm) or less. puller. When replacing tapered roller bearings,
replace both cups and cones. DO NOT use new cone
c. Remove shaft wrapping and reinstall the input side assemblies with worn (old) cups.
seal covers, Ref. #13 and 15.
17. Use a wheel puller or press to remove gears Ref.
8. DRIVE REPAIR IS COMPLETE — Review instructions #1A4 or 4A4 from the shaft. Exercise caution to avoid
in Section I for reassembly of drive onto driven shaft. scoring shaft seal diameter with the keyway of gear.
9. When seals, Ref. #19 & #20, are to be reused 18. Inspect all fasteners for damage or wear and replace
(replacement is recommended), wrap the input shaft with fasteners of equal grade. Grade 5
keyway and output shaft threads with masking tape fasteners have three (3) radial lines on the
or lightweight Kraft paper to protect seal lips during head. Fasteners are available in kit form,
disassembly. Cover wrapping with a light coat of Ref. #80.
grease.
19. If the shaft assemblies can be reused intact (no new
10. If drive is equipped with a backstop, remove output parts required), refer to Section III, Steps 6 thru 9, for
side end cover Ref. #16, gasket Ref. #23, backstop reassembly procedure. Replace all shim-gaskets with
Ref. #5A1, and key Ref. #5A4 from output housing Ref. new parts, Kit Ref. #100. On sizes 5107 and 5115, use
#11 (note the direction of rotation of the input shaft for the same thicknesses as removed during disassembly.
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.

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(Page 14 of 52) Sizes 5107-5315

IDENTIFYING & ORDERING PARTS RECOMMENDED SPARE PARTS

1. Refer to the drive component diagram, Figure 18, and 1. For non-critical drive applications, a complete set of
exploded parts diagram, Figure 19, and make a list bearings, seals and shim-gaskets is recommended.
of the parts required by part reference number. For If stored in their original packaging in a dry, cool
example, Ref. #15, 20 100, 1A, 2A1, and 2A2. When a location, these parts have a minimum shelf life of
gasketed joint is separated, always replace with new five years.
shim-gaskets. Order Ref. #100 shim-gasket kit. 2. For critical drive applications (where an outage would
2. Now refer to the parts list, Table 11, and determine the create a major production loss), a complete drive is
part description and Falk part number using the part recommended.
reference number (Step 1) and the drive identification
(e.g. 5107J25) in the column headers of the parts list.
Figure 18
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 OUTPUT HOUSING HALF
INPUT HOUSING HALF
would be ordered as follows:
AIR VENT
Seal cover . . . . . . . . . . . 4723094
Seal . . . . . . . . . . . . . . 2921419
LOW-SPEED
Shim-gasket kit . . . . . . . . 4729429 SHAFT COVER
Shaft assembly with gear . . . 4729373
Bearing . . . . . . . . . . . . 2926359 LOW-SPEED
GEAR
Bearing . . . . . . . . . . . . 2926359
4. Table 12 and 13 convert Falk part numbers to
bearing and seal manufacturer’s part numbers. Tooth
combinations are listed in Appendix G. HIGH-SPEED GEAR
METAL SHIMS
5. Place your order with your local Rexnord distributor. If LOW-SPEED
PINION
you need to locate a distributor, phone (414)342-3131 ASSEMBLY
in the United States or Canada. LOW-SPEED
HIGH-SPEED PINION
SEAL COVER
HIGH-SPEED
SHAFT COVER
(BACKSTOP COVER)
BACKSTOP
GASKET
HIGH-SPEED
SHAFT ASSEMBLY HIGH-SPEED PINION
GASKET
ELIMINATOR

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Sizes 5107-5315 (Page 15 of 52)

Figure 19 4A5
4A2

4A1 4A5
4A2

4A1

4A3

4A3
4A4

2A4
2A2
2A5 2A1 4A4

3A2
3A1
3A4
2A6
2A3

1A4 3A3

1A2

1A1 TYPE
J09, J14 & J25
1A5

TYPE J05
1A3

25
11
4A ASSY.
19

30
10
27
4A ASSY
. 25
16 23
5A5 31
17 23 .
2A ASSY

5107J & 5A ASSY. 22 19 13

5115J ONLY 29 1 ASSY.

3A ASSY
.

24
5A4 20
15
6A4 29

6A1
6A3
23 5A2 5A6 5A1
5A3 6A ASSY.

5115 J25
ONLY 5215 THRU 5315

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TABLE 11 — Parts List of Falk Part Numbers

Ref. DRIVE SIZE
Part Description
No 5107  5115  5203  5207 5215 5307 5315
Housing Components
13 Shaft Cover-LS 2109906 1164350 1164353 2110134 1164359 2110504 2110779
15 Seal Cover 4723094 4723095 4723096 4723097 4723098 4723099 4723109
16 Shaft Cover 1161865 1161866 1238030 2119130 1161870 1161870 1161870 
16 Shaft Cover W/BKSP 1243290 1161866 1238019 2119130 1219342 1237944 1219342
17 Cover Spacer BKSP 1243292 1243296 2119132
19 Seal, 2916797 2921425 2921422 2921421 2904606 2921423 2922295
20 Seal, HS 2921419 2921416 2902929 2921417 2921420 2916797 2920669
30 Air Vent 0914088 0914088 0914088 0914088 0914088 0914088 0914088
80 Fastener Kit 4729000 4729000 4729032 4729049 4729064 4729082 4729100
100 Shim & Gasket Kit 4729429 4729430 0786836 0786837 0786838 0786839 0786840
Rotating Elements — J05
3A Shaft Ass'y-Inc 3A1-3A4 4729363 4729377 4729045 4729061 4729076 4729094 4729112
3A1 Bearing 2926357 2926361 2919339 2918700 2919359 0921354 2919215
3A2 Bearing 2926357 2919340 2919340 0921521 2919360 2916263 0921853
3A3 Pinion & Shaft-Inc 3A4 4729364 4729378 4729046 4729062 4729077 4729095 4729113
4A Shaft Ass'y-Inc 4A1-4A5 4729365 4729033 4729047 4729063 4729078 4729096 4729114
4A1 Bearing 4729014 4720891 2911822 2905191 0921778 0921727 0921366
4A2 Bearing 4729014 4720891 2911822 2905191 0921778 0921727 0921366
4A3 Hollow Shaft w 4A5 Key 4729016 4723015 4723028 4723039 4723050 4723061 4723073
4A4 Gear 1242585 1238105 1242878 1237897 1242848 1242860 1237763
5A Backstop Ass'y 0795654 0793995 0785596 0783905 0785610
Rotating Elements — J09
1A Shaft Ass'y W/O 1A4 Gear 4729366 4729380 4729037 4729053 4729068 4729086 4729104
1A Shaft Ass'y With 1A4 Gear 4729367 4729381 4729034 4729050 4729065 4729083 4729101
1A1 Bearing 2926357 2926361 2919339 2918700 2919359 0921354 2919215
1A2 Bearing 2926357 2919340 2919340 0921521 2919360 2916263 0921851
1A3 Pinion & Shaft w 1A5 Key 4729368 4729382 4729041 4729056 4729071 4729089 4729107
1A4 Gear 1242532 1242536 1242834 1242842 1242849 1242857 1242861
5A Backstop Ass'y 0795654 0793995 0785596 0783905 0785610 0785529 0757183
Rotating Elements — J14
1A Shaft Ass'y W/O 1A4 Gear 4729369 4729383 4729038 4729054 4729069 4729087 4729105
1A Shaft Ass'y With 1A4 Gear 4729370 4729384 4729035 4729051 4729066 4729084 4729102
1A1 Bearing 2926357 2926361 2919339 2918700 2919359 0921354 2919215
1A2 Bearing 2926357 2919340 2919340 0921521 2919360 2916263 0921851
1A3 Pinion & Shaft w 1A5 Key 4729371 4729385 4729042 4729057 4729072 4729090 4729108
1A4 Gear 1242533 1242537 1242833 1242843 1242850 1242858 1237856
1A5 Backstop Ass'y 0795654 0793995 0785596 0783905 0785610 0785529 0757183
Rotating Elements — J25
1A Shaft Ass'y W/O 1A4 Gear 4729372 4729386 4729039 4729055 4729070 4729088 4729106
1A Shaft Ass'y With 1A4 Gear 4729373 4729387 4729036 4729052 4729067 4729085 4729103
1A1 Bearing 2926357 2926361 2919339 2918700 2919359 0921354 2919215
1A2 Bearing 2926358 2926359 2919340 0921521 2919360 2916263 0921853
1A3 Pinion & Shaft w 1A5 Key 4729374 4729388 4729043 4729058 4729073 4729091 4729109
1A4 Gear 1242534 1238106 1238017 1242844 1242851 1242859 1237764
1A5 Backstop Ass'y 0795655 0795658 0785596 0783905 0785610 0785529 0757183
Rotating Elements — J09, J14, & J25
2A Shaft Ass'y-Inc 2A1-2A6 4729375 4729389 4729040 4729059 4729074 4729092 4729110
2A1 Bearing 2926359 2926360 2919338 2918700 0921350 0921793 0921850
2A2 Bearing 2926359 2926360 2919338 2918701 2916288 0921793 0921850
2A3 Pinion & Shaft w 2A4 Key 4729376 4729390 4729044 4729060 4729075 4729093 4729111
2A5 Spacer 1179876 1179877
2A6 Spacer 1161925 1163034 1161889 1163762 21200246
4A Shaft Ass'y-Inc 4A1-4A5 4729365 4729033 4729047 4729063 4729078 4729096 4729114
4A1 Bearing 4729014 4720891 2911822 2905191 0921778 0921727 0921366
4A2 Bearing 4729014 4720891 2911822 2905191 0921778 0921727 0921366
4A3 Hollow Shaft w 4A5 Key 4729016 4723015 4723028 4723039 4723050 4723061 4729115
4A4 Gear 1242585 1238105 1242878 1237897 1242848 1242860 1237763

Continued on next page.

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 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. DRIVE SIZE
Part Description
No. 5107  5115  5203  5207 5215 5307 5315
Shaft Fan Assembly — All Ratios

6A Shaft Fan Ass'y Inc 6A1-6A4 ... ... ... ... 0785611 0785530 0785432
6A1 Fan ... ... ... ... 4729079 4729097 4729116
6A3 Guard ... ... ... ... 4729080 4729098 4729117
6A4 Backplate ... ... ... ... 4729081 4729099 4729118
c 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  TABLE 13 — Viton Seal Cross Reference
Falk Part Number Manufacturer’s Number Numbers
Tapered Roller Bearings  Manufacturer’s Number 
Falk Part Number
0921350 HM804843/HM804810 Chicago Rawhide National
0921354 475/472
0921366 48393/48320 2902929 13661 ...
0921521 19138/19283-B 2904606 42433 ...
2916797 21091 ...
0921727 68462/68712 2920669 23843 ...
0921778 JM822049/JM822010
0921793 HM803149/HM803110 2921416 11207 470712V
0921850 JHM807045/HM807010 2921417 15138 ...
2921419 8704 481570V
0921851 46176/46368 2921420 18582 ...
0921853 46162/46368
2905191 497/492A 2921421 33699 ...
2911822 34478/34300 2921422 29912 415995V
2921423 46155 ...
2916263 418/414 2921425 27324 455315V
2916288 3879/3820 2922295 52498 ...
2918700 350A/352
2918701 339/332 c Subject to substitution of equivalent seals without notice.

2919215 HM813841A/HM813810
2919338 26112/26283-S
2919339 LM48548A/LM48510
2919340 17098/17244-B
2919359 386A/382A
2919360 3379/3320-B
2926357 30205M
2926358 30303M
2926359 30304M
2926360 30305M
2926361 30206M
4720891 29675/29620
4729014 JLM506810/JLM506849
c 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.

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(Page 18 of 52) Sizes 5107-5315

Section III
DRIVE REASSEMBLY
REFER TO PARTS DRAWING FIGURE 19 3. High-speed SHAFT ASSEMBLY — Ref. #1A or
3A Assembly.
1. GENERAL
Seat heated bearings cones, Ref. #1A1, 1A2
a. Clean all parts to be reassembled and coat all
or 3A1 & 3A2, firmly against shaft shoulder or
tapered roller bearing cups and pinion teeth with
retaining ring.
an SAE 20 (or heavier) oil. DO NOT lubricate gear
teeth prior to assembly on shaft. CAUTION: Allow bearings to cool. Apply a
coat of oil to the cooled bearings to lubricate
b. Heat all ball bearings and tapered roller bearing
and avoid scoring of working surfaces.
cones in an oven to 275°F (135°C).
CAUTION: Do not apply flame directly to bearings
or rest bearings directly on a heated surface.
Figure 21
c. Slide or press all ball bearings and bearing cones
tight against the shoulder.
CAUTION: Do not apply force to the bearing rollers SHAFT
or roller cage. Apply force against the inner race EXTENSION
only.
2. ASSEMBLY OF TAPERED ROLLER BEARING CUPS
a. SIZE 5107 THRU 5315 — Drive high-speed
bearing cup, Ref. #1A2 or 3A2, intermediate-speed 1A1 BEARING
bearing cup Ref. 2A2, and low-speed bearing cup
4A2 squarely into their respective bearing bores of RETAINING
output housing Ref. #11, with a press or steel bar RING 5107
as shown in Figure 20 THRU 5215
J25 ONLY
PINION
Figure 20

1A2 BEARING

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4. INTERMEDIATE SHAFT ASSEMBLY — Ref. #2A a. Heat gear, Ref. #4A4, to 325°F (163°C) in an
Assembly - Type J09, J14 and J25 - Figure 22. Prepare oven. Insert gear key, Ref. #4A5, into hollow shaft
bearings per Steps 1b and c on Page 18. keyway. Assemble the gear with the chamfer
toward the shoulder on the shaft using a press to
ensure a tight fit.
Figure 22 2A1 BEARING 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
1A4
2A5 SPACER GEAR
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
2A6 SPACER
the working surfaces.
6. BEARING ADJUSTMENT
a. SIZES 5107 THRU 5315 — Bearing adjustment is
made by adjusting thickness of metal shims, Ref.
2A2 BEARING #24, behind bearing cups in input housing, Ref.
#10.
NOTE: The thickest shim should be located
a. ALL SIZES — Heat gear Ref. #1A4 to 325°F (163°C)
adjacent to the bearing cup. The thinnest shims
in an oven. Insert key, Ref. #2A4, in shaft keyway.
should be located in the center of the shim pack.
Assemble gear onto shaft, with the chamfer toward
pinion, using a press to ensure a tight fit. Allow (1) Support input housing, such that when high-
gear to cool before proceeding. speed shaft assembly, Ref. #1A or 3A, is
lowered into place there is clearance for shaft
b. Assemble spacer, Ref. #2A6, onto intermediate
extension end. Install bearing cups in input
shaft (except sizes 5307 and 5315). Seat bearings
housing without any metal shims. Tap dowel
or cones, Ref. #2A1 & 2A2, on shaft. Seat all
pins into input housing with solid pin nearest
components firmly so spacers do not rotate on
high-speed shaft bore.
shaft.
(2) Lower low-speed shaft assembly, Ref. #4A,
CAUTION: Allow assembly to cool. Apply a coat
into input housing, Ref. #10, with threaded
of oil to the cooled bearings to lubricate and avoid
end facing up (DO NOT install Ref. #1A [or 3A]
scoring of the working surfaces.
or 2A shaft assemblies at this time).
5. LOW-SPEED SHAFT ASSEMBLY — Ref. #4A
(3) Assemble output housing, Ref. #11, to input
Assembly - ALL TYPES - Figure 23. Prepare bearing
housing. Install housing flange fasteners, Ref.
cones per Steps 1b and c.
#25, with heads of cap screws against input
housing. Cross tighten fasteners to torque
Figure 23 specified in Table 14.)

4A1 BEARING TABLE 14 — Housing Flange Fastener Size &

SHAFT SEAL
DIAMETER
Tightening Torque ±5%
(Non-Lubricated Fasteners)
4A4 GEAR Tightening Torque
DRIVE SIZE Fastener Size
lb-ft (Nm)
5107 .312-18 19 (26)
5115 .312-18 19 (26)
5203 .375-16 27 (37)
5207 .500-13 67 (91)
5215 .500-13 67 (91)
5307 .500-13 67 (91)
5315 .500-13 67 (91)

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

SHAFT SEAL dial indicator, in accordance with method
4A2 BEARING DIAMETER described on the following page.

4A3 HOLLOW SHAFT

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(5) Low-speed shaft axial float measurement — Ref. produce the desired preload.
#4A Assembly – For drives equipped with TA (6) With drive resting on input housing cover, Ref.
Taper bushing, carefully thread bushing nut onto #10, tap the dowel pins out of the housing,
hollow low-speed shaft threads. Rotate shaft to remove flange fasteners and set output housing
seat cone assemblies in bearing cups. Set up a aside. Remove low-speed shaft assembly
dial indicator on output housing as illustrated in and bearing cups. Install metal shim(s), as
Figure 24. Indicator tip must rest on low-speed determined in Step 6b5, behind bearing cup in
shaft and not on nut surface. Rotate and oscillate input housing.
shaft with axial force applied in both directions to
obtain axial float measurement. Reinstall dowels, shims and output housing
cover & torque housing flange fasteners, Ref.
#25, to value in Table 14. Proceed to Step 7.
DIAL INDICATOR TIP MUST
REST ON QUILL SHAFT AND (7) Lower low-speed, Ref. #4A, high-speed, Ref.
NOT ON NUT SURFACE DIAL INDICATOR
WITH STAND
#1A (or 3A), and intermediate, Ref. #2A shaft
210 12 BUSHING NUT assemblies into input housing. Reinstall dowels
345 4 3 THREADED ON and output housing and torque flange fasteners
QUILL SHAFT
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
PRY BAR
Figure 24 shaft float with a dial indicator in accordance
with methods described below.
(8) INTERMEDIATE SHAFT AXIAL FLOAT
For drives without the TA Taper bushing, insert MEASUREMENT — Ref. #2A Assembly –
hollow shaft thrust plate and secure with retaining Figure 25. Remove pipe plug from output
ring as illustrated in Section I, Figure 5. Thread housing cover. Install a .375-16 x 2” size bolt
a bolt into the thrust plate. Set up a dial indicator through hole in housing and turn by hand until
on output housing, as illustrated in Figure 24, with snug. Set up a dial indicator on output housing
the indicator tip on end of hollow shaft. Rotate with the indicator tip on bolt head as illustrated
and oscillate shaft with axial force applied in in Figure 26. While turning bolt in a clockwise
both directions to obtain axial float measurement direction, lift upward to measure axial float.
(upward force can be applied by applying upward Subtract from this reading the axial float for the
force on head of thrust plate bolt). Ref. #2A shaft assembly shown in Table 15.
Refer to Table 15 and note the preload specified This indicates the thickness of metal shim(s),
for bearings 4A1 and 4A2. Add to upper and Ref. #22 to be added behind the input housing
lower limits shown, the axial float measured. bearing cup to obtain the specified axial float.
This will indicate thickness of metal shim(s), Ref.
Figure 25
#31, to be added behind input housing bearing
cup to obtain the specified preload. Table 16
provides shim thickness for each shim pack to TURN AND MOVE
assist in obtaining the desired results. BOLT TO CHECK
FLOAT

TABLE 15 — Preload & Axial Float Settings

Ref. #2A3 Ref. # 1A3 or 3A3
Assembly
Ref. # 4A1 & 4A2 Assembly
DRIVE Intermediate
Bearing Preload High-speed Shaft
SIZE Shaft
Inches (mm) Axial Float
Axial Float Inches (mm)
Inches (mm)
5107 0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)
5115 0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)
5203 0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)
5207 0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)
5215 0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)
5307 0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08) For example, from Table 15 the desired axial
5315 0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)
float for the size 5307 intermediate shaft
assembly, Ref. #2A, is .001” to .003” (0.03 mm
For example, from Table 15 the desired bearing to 0.08 mm). If the measured axial float is .039”
preload for the size 5203 low-speed shaft (0.99 mm) then addition of metal shims with
bearings, Ref. #4A1 & 4A2, is .002” to .004” a total thickness between .036” to .038” (0.91
(0.05 mm to 0.10 mm) tight. If the measured mm to 0.96 mm) behind the intermediate-speed
axial float is .039” (0.99 mm) then addition of input housing bearing cup will produce the
metal shims with a total thickness between desired axial float.
.041” to .043” (1.04 mm to 1.09 mm) behind
the low-speed input housing bearing cup will

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Sizes 5107-5315 (Page 21 of 52)

Figure 26 Figure 27 BEAD OF

LOCTITE 587
INPUT
HOUSING

1A/3A SHAFT
ASSEMBLY

9) High-speed Shaft Axial Float Measurement (12) Check intermediate and high-speed shaft
— Ref. #1A or 3A Assembly – Figure 26. Set axial floats with dial indicator to ensure they
up a dial indicator as illustrated in Figure 26 are within specified limits. If necessary,
to measure axial float of output end of shaft. disassemble drive. Clean Loctite 587 from
Push upward on shaft extension end with a housing flanges. Readjust metal shims behind
twisting motion to obtain reading. Subtract input housing bearing cups, reapply Loctite
from this reading the axial float for the Ref. #1A 587, and reassemble. Repeat until specified
(or 3A) shaft assembly shown in Table 15. This float is achieved.
indicates the thickness of metal shim(s), Ref. 7. BACKSTOP INSTALLATION
#24, to be added behind the input housing
bearing cup to obtain the specified axial float. If drive will be installed on the driven equipment
using a TA tapered bushing, do not install backstop
WARNING: Cover shaft extension end keyway at this time. If not, refer to Appendix B, for installation
with tape to avoid lacerations to the hand. instructions.
(10) Disassemble drive once more to add metal 8. SHAFT COVER INSTALLATION
shim(s) behind input intermediate and high-
speed housing bearing cups to obtain the Assemble output side high-speed shaft cover, Ref.
specified axial float shown in Table 15. #16, and gasket, Ref. #23 (Table 16). Cross tighten
fasteners to 3.5 lb-ft (4,7 Nm) torque.
(11) Apply a bead of Loctite 587 to input housing
flange as shown in Figure 27. Assemble output 9. SEAL INSTALLATION
housing to input housing and install dowels. Refer to Section II, Step 7. Position input end low-
Install and cross tighten flange fasteners to speed and high-speed shaft covers, Ref. #13 & 15,
torque specified in Table 14. 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

Ref. Shim Thickness DRIVE SIZE
No. Inch (mm) 5107 5115 5203 5207 5215 5307 5315
100 ... 4729429 4729430 0786836 0786837 0786838 0786839 0786840
.002 (0.05) 793762 793770 0787097 0781116 0787109 0787080 0785034
.005 (0.13) 793763 793771 0787098 0781117 0787110 0787081 0785035
22 .010 (0.25) 1242592 1242594 1238022 1237213 1238062 1237946 1237766
.030 (0.76) 793764 793772 0787099 0781118 0787111 0787082 0785036
23 (w/o backstop)  .031 (0.79) 1243291 1243297 2120198 2119131 1161876 1161876 1161876
23 (with backstop)  .031 (0.79) 1243291 1243297 1238020 2119131 1189882 2120077 1189882
.002 (0.05) 793762 793770 0787100 0781116 0787106 0787083 0785037
.005 (0.13) 793763 793771 0787101 0781117 0787107 0787084 0785038
24 .010 (0.25) 1242592 1242594 1238023 1237213 1238061 1237947 1237767
.030 (0.76) 793764 793772 0787102 0781118 0787108 0787085 0785039
.002 (0.05) 793758 793766 0787094 0781113 0787112 0787077 0785031
.005 (0.13) 793759 793767 0787095 0781114 0787113 0787078 0785032
31 .010 (0.25) 1242591 1242593 1238021 1237212 1238063 1237945 1237765
.030 (0.76) 793760 793768 0787096 0781115 0787114 0787079 0785033
c Ref. Number 23 Gasket compresses to .028 (0.71); all others are metal shims.

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(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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Appendix N: Reliability Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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Sizes 5107-5315 (Page 23 of 52)

Lubrication Recommendations
INTRODUCTION SYNTHETIC LUBRICANTS (TABLES 6A, 6B & 6C) —
Synthetic lubricants of the polyalphaolefin (PAO) type
Carefully follow instructions on the drive nameplate, are recommended for cold climate operation, high
warning tags and installation manuals furnished with the temperature applications, extended temperature range
drive. (all season) operation and/or extended lubricant change
Lubricants listed in this manual are typical products intervals. The proper viscosity grade of synthetic lubricant
ONLY and should not be construed as exclusive is given in Table 4.
recommendations. Industrial type petroleum-based rust Polyalkylene glycols (PAG) are another class of synthetic
and oxidation inhibited (R & O), industrial type extreme lubricants. They have similar performance properties
pressure (EP) or industrial type micropitting resistant gear as PAO synthetics — low pour point, stable at elevated
lubricants are the recommended gear lubricants. They can temperatures, and high viscosity index. PAG's have
be formulated using petroleum or synthetic base stocks. exceptional tolerance to water contamination.
The section on food grade lubricants provides guidance WARNING: Polyalkylene glycols (PAG’s) are not
selecting lubricants for applications needing this class of compatible with petroleum mineral oil or PAO synthetic
lubricants. Food grade lubricants are formulated using lubricants and must not be topped off with either lubricant.
petroleum or different types of synthetic base stocks. In addition, petroleum mineral oils or PAO synthetic
LUBRICANT SELECTION PROCESS lubricants must not be used to top off systems containing
1. Refer to Table 3 or 4 for proper lubricant viscosity PAG’s. Do not use PAG’s in gear drives with painted interior
grade based on ambient temperature range. See Falk housing walls unless paint compatibility is checked.
GMax 6000 paragraph on this page for ambient air Compatibility with oil seals and gasket materials must be
temperature range if using this lubricant. checked prior to use. PAG lubricants are not compatible
with polycarbonate sight glass. Use glass sight glass.
2. Refer to Table 1 for summary of lubricant type.
Falk GMax 6000 — Rexnord markets Falk GMax 6000, a
3. Using proper lubricant table and viscosity grade, polyalkylene glycol lubricant. It is available in ISO VG 135
select desired lubricant manufacturer name. and covers ambient air temperature range -30° to +125°F
4. Refer to Table 2 for approximate oil capacity to (-34° to +52°C). Gear drives equipped with internal
purchase. backstop can use GMax in ambient temperatures above
-20°F (-29°C).
TABLE 1 — Summary of Lubricant Type and
Greases WARNING: GMax 6000 is not compatible with petroleum
mineral oil or PAO synthetic lubricants and must not be
Petroleum-Based
topped off with either lubricant. In addition, petroleum
R & O Inhibited Extreme Pressure (EP)  Micropitting Resistant  mineral oils or PAO synthetic lubricants must not be used
See Table 5A See Table 5B See Table 5C to top off systems containing GMax 6000. Do not use
Synthetic Lubricant, Polyalphaolefin Type (PAO) GMax 6000 in gear drives with painted interior housing
walls unless paint compatibility is checked. Compatibility
R & O Inhibited Extreme Pressure (EP)  Micropitting Resistant  with oil seals and gasket materials must be checked prior
See Table 6A See Table 6B See Table 6C to use. GMax 6000 is not compatible with polycarbonate
Synthetic Lubricant, Polyalphaolefin Glycol Type (PAG) sight glass. Use glass sight glass.
See Falk GMax 6000 (Paragraph to Right) ANTI-WEAR (AW) LUBRICANTS — For moderately
Conventional Grease loaded gear drives or operating conditions challenging
See Table 7
for conventional R & O oils, industrial type anti-wear (AW)
lubricants are suggested. These lubricants contain anti-
Food Grade Lubricant & Grease wear additives that provide stronger thicker lubricant film
See Page 28 to help maintain surface separation. Synthetic lubricants
 DO NOT use in drives equipped with internal backstop. by inherent nature of base stock properties provide anti-
wear performance.
VISCOSITY (IMPORTANT)
The proper viscosity grade for petroleum-based lubricant EXTREME PRESSURE (EP) LUBRICANTS (TABLES 5B
is found in Table 3. For synthetic lubricant viscosity grades, & 6B) — For highly loaded drives or for drives loaded in
refer to Table 4 and the “Synthetic Lubricants” paragraphs. excess of original estimates, industrial-type petroleum EP
lubricants are preferred. EP lubricants are manufactured
Viscosity grade is determined by ambient air temperature from petroleum or synthetic base lubricants. Anti-scuff is
in immediate vicinity of gear drive. Lubricant selections another term used to describe EP lubricants.
must have a pour point at least 10°F (5.5°C) below the
expected minimum ambient starting temperature. CAUTION: EP LUBRICANTS & INTERNAL BACKSTOPS
— Do not use EP lubricants or lubricant formulations
including sulfur-phosphorus (EP), chlorine, lead
LUBRICANT TYPES derivatives, graphite or molybdenum disulfides in drives
PETROLEUM-BASED LUBRICANTS (TABLEs 5A, 5B & equipped with internal cartridge type backstops. Lubricant
5C) — Industrial type petroleum-based rust and oxidation formulations may change over time. Some lubricants in
inhibited (R & O) gear lubricants are the most common and Tables 5A & 6A may contain higher amounts of additives
readily available general purpose gear lubricants. to reduce friction, resulting in lubricant properties

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(Page 24 of 52) Sizes 5107-5315

approaching that of extreme pressure (EP) lubricants; end TABLE 3 — Viscosity Grade Recommendations
user should consult lubricant manufacturer/supplier and For Petroleum-Based Lubricants
Rexnord as necessary. Typically EP lubricants in Tables 5B
& 6B contain these additives. Ambient Temperature +30° to +90°F +70° to +125°F
Range (-1° to +32°C) (+21° to +52°C)
MICROPITTING RESISTANT LUBRICANTS (TABLES 5C ISO Viscosity Grade 220 320
& 6C) — Micropitting resistant lubricants are specially AGMA Viscosity Grade 5 6
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 LUBRICANT ANALYSIS AND CHANGES
drives or applications where operating loads are not well
defined may benefit from this type of lubricant. Generally OIL ANALYSIS REPORT — Checking oil condition at
lubricants are available in limited number of viscosity regular intervals is recommended. Analyze oil samples
grades. approximately every 1000 hours for petroleum lubricants
or every 3000 hours for synthetic lubricants. In the
CAUTION: MICROPITTING RESISTANT LUBRICANTS absence of more specific limits, the guidelines listed below
& INTERNAL BACKSTOPS — Do not use micropitting may be used to indicate when to change petroleum or
resistant lubricants in drives equipped with internal polyalphaolefin type synthetic lubricants:
cartridge type backstops. These lubricants are listed in
1. Water content is greater than 500 ppm (parts per
Tables 5C & 6C.
million) (0.05%).
WARNING: LUBRICANTS IN FOOD PROCESSING 2. Iron content exceeds 150 ppm.
INDUSTRY — Generally conventional gear lubricants are
classified as H2 by NSF (National Sanitation Foundation) 3. Silicon (dust/dirt) exceeds 25 ppm, above reference
since they contain harmful substances and should not sample from new oil container.
be used in the food processing industry. Lubricants 4. Copper content exceeds 75 ppm.
registered as H1 by NSF are suitable for food processing 5. TAN (Total Acid Number) 50% increase above
applications. reference sample from new oil container.
CLIMATE CONDITIONS — Ambient temperature in 6. Viscosity changes more than ±15%.
immediate vicinity of gear drive is very important for 7. Solid particle contamination code exceeds 25/22/18
determining viscosity grade. Table 3 provides viscosity for particle sizes ≥4/≥6/≥14 microns, respectively per
grade selections for petroleum-based lubricants. See ISO 4406.
Table 4 for synthetic lubricants.
Guidelines for when to change Falk GMax 6000
polyalkylene glycol type lubricant are:
OIL LEVELS
1. Water content is greater than 3%.
Fill the drive with lubricant to pipe plug level indicated in
illustrations in Section 1. Approximate oil capacities are 2. Iron content exceeds 150 ppm.
given in Table 2 below. 3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
TABLE 2 — Approximate Oil Capacity – 5. Viscosity changes more than ±15%.
Quarts (Liters)  6. Solid particle contamination code 25/22/18 per ISO
DRIVE SIZE JR, JF & JSC JRV & JFV 4406.
5107 2 (1.9) 3 (2.8) Laboratory analysis is recommended for optimum lubricant
5115 3 (2.8) 4.5 (4.3) life and gear drive performance.
5203 3.5 (3.3) 5 (4.7)
5207 5.5 (5.2) 7.5 (7.1)
5215 9 (8.5) 13 (12.3)
5307 13 (12.3) 18 (17)
5315 15 (14.2) 21 (19.9)
c Quantities are approximate. Always fill drive to specified level.

TABLE 4 — Viscosity Grade Recommendations For Synthetic Lubricants

Ambient Cold Climates Normal Climates
Temperature –30° to +10°F –15° to +50°F 0° to +80°F +10° to +125°F  +20° to +125°F
Range (–34° to –12°C) (–26° to +10°C) (–18° to +27°C) (–12° to +52°C) (–7° to +52°C)
ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade O 2 4 5 6
c Gear drives NOT equipped with internal backstop may widen the ambient temperature range to -18° to +125°F (-28° to +52°C).

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 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 200°F (93°C)
ISO Viscosity Grade 220 320
AGMA Viscosity Grade 5 6
Viscosity cSt @ 40°C  198-242 288-352
Viscosity SSU @ 100°F 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name
Hyspin AWS 220 ---
Castrol Industrial Lubricants Castrol Paradene R&O 220 Castrol Paradene R&O 320
Castrol Paradene AW 220 Castrol Paradene AW 320
Chevron / Texaco / Caltex Rando HD 220 Rando HD 320
Citgo Petroleum Corp. Pacemaker SD 220 Pacemaker SD 320
DTE Oil BB DTE Oil AA
Exxon Mobil / Esso Vacuoline 533 Vacuoline 537
Petro-Canada Lubricants TurboFlo R&O 220 TurboFlo R&O 320
Phillips 66 / Conoco / 76 Lubricants / Kendall Multipurpose R&O 220 Multipurpose R&O 320
Morlina S2 B 220 Morlina S2 B 320
Shell Oil Co. Morlina S2 BA 220 Morlina S2 BA 320
Total Lubricants USA / Keystone Div. Penwalt Corp. Cirkan ZS 220 Cirkan ZS 320
Whitmore Manufacturing Company Hyperion 220 Hyperion 320
c 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 200°F (93°C)
ISO Viscosity Grade 220 320
AGMA Viscosity Grade 5 6
Viscosity cSt @ 40°C n 198-242 288-352
Viscosity SSU @ 100°F 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name
Castrol Industrial Lubricants Alpha SP 220 Alpha SP 320
Meropa 220 Meropa 320
Chevron / Texaco / Caltex Ultra Gear 220 Ultra Gear 320
Citgo Petroleum Corp. EP Compound 220 EP Compound 320
Exxon Mobil / Esso Mobilgear 600 XP 220 Mobilgear 600 XP 320
Fuchs Lubricants Company GearMaster CLP Oils 220 ---
Petro-Canada Lubricants Enduratex EP 220 Enduratex EP 320
Phillips 66 / Conoco / 76 Lubricants / Kendall Extra Duty Gear Oil 220 Extra Duty Gear Oil 320
Shell Oil Co. Omala S2 G 220 Omala S2 G 320
Total Lubricants USA / Keystone Div. Penwalt Corp. Carter EP 220 Carter EP 320
c 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 200°F (93°C)
ISO Viscosity Grade 220 320
AGMA Viscosity Grade 5 6
Viscosity cSt @ 40°C n 198-242 288-352
Viscosity SSU @ 100°F 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name
Kluber Lubrication Kluberoil GEM 1 N 220 Kluberoil GEM 1 N 320
c 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.

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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 32 68 150 220  320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C  28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
Alphasyn T 32 Alphasyn T 68 Alphasyn T 150 Alphasyn T 220 Alphasyn T 320
Castrol Industrial Lubricants
Castrol Isolube 32 Castrol Isolube 68 Castrol Isolube 150 Castrol Isolube 220 Castrol Isolube 320
Chevron / Texaco / Caltex Cetus HiPerSYN Oil 32 Cetus HiPerSYN Oil 68 Cetus HiPerSYN Oil 150 Cetus HiPerSYN Oil 220 Cetus HiPerSYN Oil 320
Citgo Petroleum Corp. --- CITGEAR Synthetic HT 68 CITGEAR Synthetic HT 150 CITGEAR Synthetic HT 220 CITGEAR Synthetic HT 320
Exxon Mobil / Esso Mobil SHC 624 Mobil SHC 626 Mobil SHC 629 Mobil SHC 630 Mobil SHC 632
Kluber Lubrication --- Klubersynth G 4 68 Klubersynth G 4 150 Klubersynth G 4 220 ---
Petro-Canada Lubricants Synduro SHB 32 Synduro SHB 68 Synduro SHB 150 Synduro SHB 220 ---
Phillips 66 / Conoco / 76 --- Syncon R&O 68 Syncon R&O 150  Syncon R&O 220  Syncon R&O 320 
Lubricants / Kendall
Shell Oil Co. --- Morlina S4 B 68 Morlina S4 B 150 Morlina S4 B 220 Morlina S4 B 320
c 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).
z Gear drives NOT equipped with internal backstop may widen the ambient tempeature range to -18° to +125°F (-28° to +52°C).
+ Minimum viscosity index of 120.

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

ISO Viscosity Grade 32 68 150 220  320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C  28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
Alphasyn EP 150 Alphasyn EP 220 Alphasyn EP 320
Castrol Industrial Lubricants --- Castrol Isolube EP 68
Castrol Isolube EP 150 Castrol Isolube EP 220 Castrol Isolube EP 320
Tegra Synthetic Gear Tegra Synthetic Gear Tegra Synthetic Gear
Chevron / Texaco / Caltex --- --- Lubricant 150 Lubricant 220 Lubricant 320
CITGEAR Synthetic CITGEAR Synthetic CITGEAR Synthetic CITGEAR Synthetic
Citgo Petroleum Corp. --- EP Gear 68 EP Gear 150 EP Gear 220 EP Gear 320
Exxon Mobil / Esso --- --- Mobil SHC Gear 150 Mobil SHC Gear 220 Mobil SHC Gear 320
Fuchs Lubricants Company --- --- --- Renolin Unisyn CLP 220 Renolin Unisyn CLP 320
Kluber Lubrication --- --- Klubersynth EG 4 150 Klubersynth EG 4 220 Klubersynth EG 4 320
Petro-Canada Lubricants --- --- Enduratex Synthetic EP 150 Enduratex Synthetic EP 220 Enduratex Synthetic EP 320
Phillips 66 / Conoco / 76 --- --- Syncon EP Plus Gear Oil 150 Syncon EP Plus Gear Oil 220 Syncon EP Plus Gear Oil 320
Lubricants / Kendall
Shell Oil Co. --- Omala S4 GX 68 Omala S4 GX 150 Omala S4 GX 220 Omala S4 GX 320
Whitmore Mfg. Company --- --- Decathlon HD 150 Decathlon HD 220 Decathlon HD 320
c 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).
z Gear drives NOT equipped with internal backstop may widen the ambient tempeature range to -18° to +125°F (-28° to +52°C).
 DO NOT use in drives equipped with internal backstop.

TABLE 6C — Synthetic PAO (Polyalphaolefin) Micropitting Resistant Lubricants  

ISO Viscosity Grade 32 68 150 220  320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C  28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
Chevron / Texaco / Caltex --- --- --- --- Pinnacle WM 320
Exxon Mobil / Esso --- --- --- --- Mobil SHC Gear 320 WT
Kluber Lubrication --- --- Klubersynth GEM 4 N 150 Klubersynth GEM 4 N 220 Klubersynth GEM 4 N 320
Petro-Canada Lubricants --- --- --- --- Harnex 320
Phillips 66 / Conoco / 76 Lubricants / Kendall --- --- --- --- Syncon WTL 320
Whitmore Manufacturing Company --- --- Decathlon F 150 Decathlon F 220 Decathlon F 320
c 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).
z Gear drives NOT equipped with internal backstop may widen the ambient tempeature range to -18° to +125°F (-28° to +52°C).
 DO NOT use in drives equipped with internal backstop.

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 Falk® Quadrive® Shaft Mounted Drives Model A • Appendix A
Sizes 5107-5315 (Page 27 of 52)

PETROLEUM LUBRICANTS — In the absence of oil WARNING: Greases in Table 7 contain harmful substances
analysis, change gear oils every 6 months or 2500 operating not allowed in the food processing industry. If grease
hours, whichever occurs first. Change oil more frequently could contaminate the product, as in the food and drug
when gear drives operate in extremely humid, chemical or industries, the grease originally supplied with gear drive
dust laden atmospheres. In these cases, lubricants should must be removed and replaced with grease listed in Table
be changed every 3 to 4 months or 1500 to 2000 hours. If 14. Refer to gear drive assembly/disassembly instructions.
the drive is operated in an area where temperatures vary Simply purging grease with grease gun will not remove all
with the seasons, change the oil viscosity grade to suit the grease and cross-contamination will likely occur. Grease
temperature, refer to Table 3. Lubricant suppliers can test registered as H1 by NSF, National Sanitation Foundation, is
oil from the drive periodically and recommend economical suitable for food processing applications.
change schedules.
SYNTHETIC LUBRICANTS — In the absence of oil
analysis, synthetic lube change intervals can be extended
STORED & INACTIVE GEAR DRIVES
to 8000 hours depending upon operating temperatures. Refer to Section II (Drive Service and Repair) for details on
Laboratory analysis is recommended for optimum lubricant stored & inactive gear drives.
life and drive performance. Change lube with change in
ambient temperature, if required. Refer to Table 4.
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 +200°F (-18° to +93°C)
Manufacturer Grease Without
EP Grease n EP Additives
Chevron / Texaco /
Caltex Multifak EP 2 ---

Citgo Petroleum Corp. Lithoplex RT 2 ---

Premium Lithium EP 2
ExxonMobil / Esso Mobilux EP 2 Unirex N2
Petro-Canada Precision General Precision XL EMB Grease
Lubricants Purpose EP2 Precision Synthetic EMB
Phillips 66 / Conoco /
76 Lubricants / Kendall Multiplex Red ---

Shell Oil Co. Gadus S1 V220-2 Gadus S2 V100 - 2

Total Lubricants USA /
Keystone Div. Penwalt Corp. 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 20°F (-7°C). If grease must be applied at cooler temperatures
consult lubricant supplier for recommendations.

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(Page 28 of 52) Sizes 5107-5315

FOOD GRADE LUBRICANTS TABLE 9 — Viscosity Grade Recommendations

Guidance for selecting petroleum-based and synthetic- For Food Grade Petroleum-Based
based food grade lubricants are shown below in Table 8. Lubricants
For general lubrication guidelines, refer to the first part of Ambient Temperature +30° to +90°F +70° to +125°F
the "Lubrication Recomendation" Section. Range (-1° to +32°C) (+21° to +52°C)
FOOD GRADE LUBRICANT SELECTION PROCESS ISO Viscosity Grade 220 320
1. Refer to Table 9 or 10 for proper lubricant viscosity AGMA Viscosity Grade 5 6
grade based on ambient temperature range.
2. Refer to Table 8 for summary of food grade lubricant
type. Polyalkylene glycols (PAG) are another class of synthetic
lubricants. They have similar performance properties
3. Using proper food grade lubricant table and viscosity
as PAO synthetics — low pour point, stable at elevated
grade, select desired lubricant manufacturer name.
temperatures, and high viscosity index. PAG's have
4. Refer to Table 2 for approximate oil capacity to exceptional tolerance to water contamination.
purchase.
WARNING: Polyalkylene glycols (PAG’s) are not
TABLE 8 — Summary of Food Grade compatible with petroleum mineral oil or PAO synthetic
Lubricants and Greases lubricants and must not be topped off with either lubricant.
In addition, petroleum mineral oils or PAO synthetic
Petroleum-Based lubricants must not be used to top off systems containing
R & O Inhibited Extreme Pressure (EP)  PAG’s. Do not use PAG’s in gear drives with painted interior
See Table 11A See Table 11B housing walls unless paint compatibility is checked.
Synthetic Lubricant, Polyalphaolefin Type (PAO) Compatibility with oil seals and gasket materials must be
R & O Inhibited Extreme Pressure (EP)  checked prior to use. PAG lubricants are not compatible
See Table 12A See Table 12B with polycarbonate sight glass. Use glass sight glass.
Synthetic Lubricant, Polyalkylene Glycol Type (PAG)
CAUTION: EXTREME PRESSURE (EP) LUBRICANTS &
Extreme Pressure (EP)  INTERNAL BACKSTOPS — Do not use EP lubricants in
See Table 13
drives equipped with internal cartridge type backstops.
Food Grade Grease These lubricants are listed in Tables 11B, 12B & 13.
See Table 14
 DO NOT use in drives equipped with internal backstop.
LUBRICANT ANALYSIS AND CHANGES
FOOD GRADE LUBRICANTS (TABLES 11A, 11B, 12A,
12B, 13 & 14) — Food grade lubricants are a class of OIL ANALYSIS REPORT (FOOD GRADE) — Checking oil
lubricants registered as H1 by NSF, National Sanitation condition at regular intervals is recommended. Analyze oil
Foundation. They contain base stock and additives which samples approximately every 1000 hours for food grade
comply with Food and Drug Administration Title 21 CFR petroleum lubricants or every 3000 hours for food grade
178.3570 regulations for lubricants with incidental food synthetic lubricants. In the absence of more specific limits,
contact. Base stock can be petroleum oil or different types the guidelines listed below may be used to indicate when
of synthetic lubricant. Food grade lubricants are not same to change food grade lubricants:
as biodegradable or environmentally friendly lubricants. 1. Water content is greater than 500 ppm (parts per
Rust and corrosion inhibitors used to protect gear drive million) (0.05%).
during shipment are not qualified as food grade fluids. Flush 2. Iron content exceeds 150 ppm.
out inhibitor oil before filling with food grade lubricant. 3. Silicon (dust/dirt) exceeds 25 ppm, above reference
Tables 11A, 11B, 12A, 12B, 13 & 14 list food grade sample from new oil container.
lubricants that have performance properties meeting 4. Copper content exceeds 75 ppm.
Rexnord/Falk specifications. They are not exclusive
5. TAN (Total Acid Number) 50% increase above
recommendations but serve as a guide for making proper
reference sample from new oil container.
lubricant selections.
6. Viscosity changes more than ±15%.
CLIMATE CONDITIONS — Ambient temperature in
immediate vicinity of gear drive is very important for 7. Solid particle contamination code exceeds 25/22/18
determining viscosity grade. Table 9 provides viscosity for particle sizes ≥4/≥6/≥14 microns, respectively per
grade selections for petroleum-based lubricants. See ISO 4406.
Table 10 for synthetic lubricants.

TABLE 10 — Viscosity Grade Recommendations for Food Grade Synthetic Lubricants

Ambient Cold Climates Normal Climates
Temperature –30° to +10°F –15° to +50°F 0° to +80°F +10° to +125°F  +20° to +125°F
Range (–34° to –12°C) (–26° to +10°C) (–18° to +27°C) (–12° to +52°C) (–7° to +52°C)
ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade O 2 4 5 6
c Gear drives NOT equipped with internal backstop may widen the ambient temperature range to -18° to +125°F (-28° to +52°C).

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 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 200°F (93°C)
ISO Viscosity Grade 220 320
AGMA Viscosity Grade 5 6
Viscosity cSt @ 40°C  198-242 288-352
Viscosity SSU @ 100°F 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name
Bel-Ray Company, Inc. No-Tox Gear Oil ISO 220 No-Tox Gear Oil ISO 320
Kluber Lubrication --- ---
Lubriplate Lubricants Co. Lubriplate FMO 1100-AW Lubriplate FMO 1700-AW
c 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 200°F (93°C)
ISO Viscosity Grade 220 320
AGMA Viscosity Grade 5 6
Viscosity cSt @ 40°C  198-242 288-352
Viscosity SSU @ 100°F 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name
Petro-Canada Purity FG EP 220 Purity FG EP 320
Total Lubricants USA, Inc. Nevastane EP 220 Nevastane EP 320
c 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 200°F (93°C)
ISO Viscosity Grade 32 68 150 220  320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C  28.2-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer 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
c 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 +125°F (-28° to +52°C).

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

ISO Viscosity Grade 32 68 150 220  320

AGMA Viscosity Grade 0 2 4 5 6

Viscosity cSt @ 40°C  28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 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 ---
c 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 +125°F (-28° to +52°C).
 DO NOT use in drives equipped with internal backstop.

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(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 200°F (93°C)
See Warning Note below.
ISO Viscosity Grade 32 68 150 220  320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C  28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100° F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer 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
WARNING: Polyalkylene glycol (PAG) lubricants are not compatible with petroleum mineral oils or PAO synthetic lubricants. PAG’s must not be mixed or
used to top off either petroleum mineral oils or PAO synthetic lubricants.
c 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 +125°F (-28° to +52°C).
 DO NOT use in drives equipped with internal backstop.

Guidelines for when to change food grade polyalkylene If grease could contaminate the product, as in the food
glycol type lubricant are: and drug industries, the grease originally supplied
1. Water content is greater than 3%. with gear drive must be removed and replaced with
2. Iron content exceeds 150 ppm. grease listed in Table 14. Refer to gear drive assembly/
disassembly instructions. Simply purging grease with
3. Silicon (dust/dirt) exceeds 25 ppm, above reference grease gun will not remove all grease and cross-
sample from new oil container.
contamination will likely occur. Grease registered as H1
4. Copper content exceeds 75 ppm. by NSF, National Sanitation Foundation, is suitable for food
5. Viscosity changes more than ±15%. processing applications.
6. Solid particle contamination code 25/22/18 per ISO 4406.
Laboratory analysis is recommended for optimum lubricant TABLE 14 — Food Grade Grease  for Grease
life and gear drive performance. Purged Seals , NLGI #2 Grade
0° to +200°F (-18° to +93°C)
PETROLEUM LUBRICANTS (FOOD GRADE) — In the
absence of oil analysis, change gear oils every 6 months Manufacturer Lubricant
or 2500 operating hours, whichever occurs first. Change Bel-Ray Company, Inc. No-Tox HD Grease 2
oil more frequently when gear drives operate in extremely
Chevron USA, Inc. (Texaco/
humid, chemical or dust laden atmospheres. In these Caltex) Chevron FM ALC EP 2
cases, lubricants should be changed every 3 to 4 months
or 1500 to 2000 hours. If the drive is operated in an area Exxon Mobil Mobil SHC Polyrex 462
where temperatures vary with the seasons, change the oil Kluber Lubrication Klubersynth UH1 14-222
viscosity grade to suit the temperature, refer to Table 9.
Lubriplate Lubriplate FGL-2
Lubricant suppliers can test oil from the drive periodically
and recommend economical change schedules. Total Lubricants USA, Inc. Nevastane HT/AW 2

SYNTHETIC LUBRICANTS (FOOD GRADE) — In the Petro-Canada Purity FG

absence of oil analysis, synthetic lube change intervals Phillips 66 / Conoco / 76
Food Machinery Grease 2
can be extended to 8000 hours depending upon operating Lubricants / Kendall
temperatures. Laboratory analysis is recommended for c NSF (National Sanitation Foundation) H1 Registered.
optimum lubricant life and drive performance. Change lube Grease application or re-lubrication should be done at temperatures
with change in ambient temperature, if required. Refer to above 20°F (-7°C). If grease must be applied at cooler temperatures
Table 10. consult lubricant supplier for recommendations.

STORED & INACTIVE GEAR DRIVES

GREASE-LUBRICATED SEALS
Prior to shipment from the factory, all Rexnord enclosed
All drives are furnished with grease purged seals which gear drives are protected internally against corrosion with
minimize the entry of contaminants and abrasive dusts into a rust preventative oil. A vapor phase rust inhibitor may
the drive. Drives are shipped with NLGI #2 grade grease also be added.
in the seal housing cavities unless otherwise specified.
WARNING: These corrosion inhibitors are not H1
Whenever changing oil in the drive, purge the seals with one registered with the NSF (National Sanitation Foundation)
of the NLGI #2 grade greases listed in Table 14. Depending as suitable for food processing applications. When Food
upon the degree of contamination, it may be necessary to Grade Lubricants are to be used, it is the end users
purge contaminated grease from seals more often (at least responsibility to properly flush and prepare the drive for
every 3 to 6 months). Slowly pump fresh bearing grease Food Grade service. Contact the lubricant manufacturer for
through the seal, WITH HAND GREASE GUN, until fresh specific information and flushing procedures.
grease flows out along the shaft. Wipe off purged grease.

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 Falk® Quadrive® Shaft Mounted Drives Model A • Appendix A
Sizes 5107-5315 (Page 31 of 52)

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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
REF. #23 GASKET
lubricants which do not contain extreme pressure (EP) REF. # 27
FASTENERS REF. #16
additives if the drive is equipped with an internal backstop. SHAFT COVER
CAUTION: Do not use EP lubricants, or lubricant
formulations including sulfur, phosphorus, chlorine, lead 2. BACKSTOP PREPARATION: Remove backstop Ref.
derivatives, graphite or molybdenum disulfides in drives #5A1 from the kit and wipe off any excess lubricant.
equipped with internal backstops. Refer to Appendix A On drive sizes 5107 (all ratios) and 5115 (24.87 ratio),
for proper selection of lubricants. Use of an improper assemble retaining ring Ref. #5A2 onto one of the
lubricant will contribute to premature wear or malfunction grooves on the backstop OD. On drive size 5115J25,
of the backstop. assemble spacer Ref. #5A6 to backstop OD adjacent
SYNTHETIC LUBRICANTS — Synthetic lubricants of the to retaining ring on inboard side. All other size 5115J
polyalphaolefin type may be used in drives with internal and larger drives, insert housing spacer Ref. #5A3
backstops. (retaining ring used as housing spacer on drive size
5207J) into housing bore adjacent to bearing cup
Before installing backstop, check direction of free rotation
(Figure 2). Assemble key Ref.#5A4 to backstop keyway
(overrunning) indicated by the arrow etched on each side
(spacer Ref. #5A6 is between retaining ring and key on
of the backstop.
511J25 backstop).

BACKSTOP APPLICATION REF.# 5A4

Backstops are designed to prevent reverse rotation Figure 1

or back-run without backlash in applications such as DRIVE SIDE
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, SHAFT
manlifts, ski tows and ski lifts. DO NOT use a backstop as a COVER
SIDE REF.# 5A3 SPACER
substitute for a brake. REF.# 5A1
REF.# 5A6 (5115J25 ONLY)
REF.# 5A2
INDEXING
DO NOT use the backstop for indexing applications. 3. ALL SIZES — BACKSTOP INSTALLATION: Apply oil
The backstop is designed to prevent reverse rotation to the O.D. of the high-speed shaft backstop journal
five times or less in eight hours, with one minute or and the sprags inside of the backstop. Align the
more in overrunning direction between backstopping backstop key with the keyway in the exposed housing
load applications. If backstopping operations are more bore and carefully slide the backstop into the bore
frequent, or the time between operations is less than one while slowly rotating the high-speed shaft. The shaft
minute, the backstop is classified as an indexing device will only rotate in one direction. DO NOT FORCE OR
and must be referred to the Factory. HAMMER; this may damage the shaft or misalign the
sprags.
INSTALLATION (Backstop Added to Existing Drive Check operation of backstop by turning high-speed
Only) shaft in required direction of rotation by hand. If the
shaft does not rotate in the required direction, remove
1. DRIVE PREPARATION: Drain oil from drive. Remove
backstop, reverse it, reposition the retaining ring and
fasteners Ref. #27, end cover Ref. #23, and gasket Ref.
spacer (where used) and reinsert it into the housing
#16, Figure 1. Keep size 5115J and 5207J end covers,
bore as instructed.
size 5207J fasteners and all lock washers for reuse, all
other parts may be discarded.

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 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 On drive sizes 5203 thru 5315, install one gasket Ref.
of rotation and then reverse the rotation to lock up #23 and backstop end cover Ref. #27 to drive housing
the backstop. Observe the position of the sprags. (one gasket Ref. #23, cover spacer Ref. #17, second
All sprags must be engaged and lay in the same gasket Ref. #23, and end cover Ref. #16 on drive size
relative position around the shaft. If the sprags are not 5207J). Size 5207J uses end cover and fasteners
uniformly positioned, lightly tap the backstop cage to removed in Step 1. Oil feed holes or slots in gaskets,
centralize all the sprags around the shaft and cage. If cover spacer (5207J), and cast shaft covers must
sprags cannot be uniformly positioned in this manner, be aligned with the housing backstop oil feed hole
remove the backstop and run a finger around the to provide proper lubrication to the backstop. Install
sprags in the overrunning direction. Reinstall backstop fasteners with lock washers and cross tighten to
as instructed in preceding steps. 8 lb-ft (11 Nm) torque.
Check the position of the sprags several times by Clean housing surface for rotation and WARNING
overrunning and locking the sprags. If all sprags move labels. Affix the rotation indicator label next to
uniformly, hold the backstop in the locked position and the high-speed shaft extension to indicate the
proceed to the next assembly step. free direction of rotation (Figure 4). Fill to oil level
4. FINAL ASSEMBLY — EXTERNAL PARTS: On drive specified in Section I with oil specified in Appendix
sizes 5107J and 5115J, install one gasket Ref. #23, A. Check motor for correct rotation before completing
cover spacer Ref. #17, spider Ref. #5A5, second connection to drive.
gasket Ref. #23, and backstop end cover Ref. #16
(size 5115J uses stamped end cover removed in Step Figure 4
1). Oil feed slots in gaskets and cover spacer must
be aligned with the housing backstop oil feed hole to DRIVE EQUIPPED
provide proper lubrication for the backstop. Refer to WITH INTERNAL BACKSTOP

figures 3A and 3B. Install fasteners with lock washers

and cross tighten to 3.5 lb-ft (4,7 Nm) torque. H.S. SHAFT ROTATION
DO NOT USE EXTREME
PRESSURE LUBRICANTS
Figure 3A 5107J WITH BACKSTOP Rexnord Industries, LLC

BACKSTOP OIL INSTALLED BACKSTOP

FEED HOLE (WITH RETAINING
GASKET
RING)

SPIDER 5A5

EXTERNAL HOUSING
SPACER WITH GASKET BACKSTOP REPLACEMENT — IN EXISTING
ON BOTH SIDES REF.#17
DRIVES WITH DAMAGED BACKSTOPS
5. DISASSEMBLY— EXTERNAL PARTS: Drain oil from
END COVER REF.#16 drive and remove backstop cover fasteners, backstop
end cover, gasket(s), cover spacer (where used),
Figure 3B 5115J WITH BACKSTOP and spider (where used). Save all metallic parts for
BACKSTOP OIL
possible reuse.
FEED HOLE 6. BACKSTOP REMOVAL: Remove backstop from drive
INSTALLED BACKSTOP and discard, keep backstop key, backstop spacer
OIL FEED
(WITH SPACER AND (5115J25 only), and backstop retaining rings (where
RETAINING RING
SLOT ON 5115J25)
used) for possible reuse. Remove housing spacer
from drive housing backstop bore and keep for reuse.
EXTERNAL HOUSING SPACER NOTE: Complete drive disassembly is required to
WITH GASKET ON BOTH SIDES
REF.#17
replace the high-speed shaft, refer to Sections II and
SPIDER 5A5
III of this manual for disassembly, parts replacement,
and reassembly of the basic drive.
7. BACKSTOP PREPARATION, BACKSTOP
STAMPED ( REF.#16) END COVER 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.

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Appendix C • Falk® Quadrive® Shaft Mounted Drives Model A
(Page 34 of 52) Sizes 5107-5315

TA Removal Tool
INTRODUCTION 2. Loosen the setscrew on the O.D. of the bushing nut
and select the most convenient of the tapped holes in
The patented TA removal tool offers a positive method
the housing face for the threaded adapter. Figure 2.
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. Figure 2
The removal tool is available in kit form suitable for use with
sizes 5107 thru 5315. The kit can be ordered from your
DO NOT USE THIS HOLE
Rexnord distributor by specifying “TA Removal Kit - Part FOR SIZES 5107 & 5115
0769406”. NOTE: Use of this tool requires a minimum axial SETSCREW
clearance “M” shown in Figure 1 and Table 1.
CAUTION: DO NOT modify the tool in any way OR use it (3) TOOL
ADAPTER HOLES
in another manner except to loosen the bushing nut as
instructed herein.

Figure 1
M

REMOVAL
TOOL
THREADED
ADAPTER

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) TABLE 2 — Adapter Tightening Torque
DRIVE SIZE M Dimension Adapter Torque
DRIVE SIZE Part Number lb-ft (Nm)
5107 2.62 (67)
5115 2.62 (67) 5107 2111955 35 (47)
5203 2.62 (67) 5115 2111956 70 (95)
5207 2.62 (67) 5203 9111957 108 (146)
5215 3.18 (81) 5207 2111958 120 (163)
5307 3.18 (81) 5215 2111959 180 (244)
5315 3.18 (81) 5307 2111959 180 (244)
5315 2111959 180 (244)
PREPARATION FOR REMOVAL
WARNING: Always “lock out” prime mover before working
on the Quadrive. 4 Mount the removal tool as illustrated in Figure 3 or 4.
1. Quadrive shafts, input and output, must be free to It is generally preferable to install the tool in a position
rotate. where its weight will tend to keep it engaged into
the nut. Then rotate the input shaft until the tool hook
a) Remove any external load on the driven shaft. engages one of the slots in the nut.
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.

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 Falk® Quadrive® Shaft Mounted Drives Model A • Appendix C
Sizes 5107-5315 (Page 35 of 52)

TA Removal Tool
Figure 3 REMOVAL OF QUADRIVE
SIZES 5107, 5115, 5203, & 5207
5. Use a spanner wrench to apply torque through the
ENGAGE TOOL input shaft keyway (Type J05 clockwise; Types J09,
IN SLOT J14 or J25 counter-clockwise) to loosen the bushing
nut.
TOOL 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
USE INNER
HOLE NOT exceed the H.S. shaft torque values listed in Table
3. NOTE: The nut will rotate freely for approximately
LOW-SPEED SHAFT
180° as it moves from the locked to the removal
ROTATION position. Resistance will indicate that unseating
is occurring. Turn until the nut and bushing are
completely free. Now, prepare the drive for lifting by
Figure 4 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.
SIZES 5215, 5307, & 4315
ENGAGE TOOL IN SLOT

TOOL
TABLE 3 — Maximum Torque – H.S. Shaft
USE OUTER lb-ft (Nm)
HOLE
Drive Reduction
LOW-SPEED SHAFT DRIVE
ROTATION SIZE J05 J09 J14 J25
5107 164 (223) 88 (120) 58 (78) 33 (44)
5115 248 (336) 133 (181) 90 (121) 50 (68)
5203 406 (550) 224 (304) 143 (193) 79 (107)
5207 493 (668) 263 (357) 173 (234) 100 (136)
5215 677 (917) 371(503) 245 (332) 133 (181)
5307 762 (1033) 405 (549) 278 (377) 150 (203)
5315 813 (1102) 432 (585) 283 (384) 160 (217)

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Appendix D • Falk® Quadrive® Shaft Mounted Drives Model A
(Page 36 of 52) Sizes 5107-5315

Motor Mount Installation

INTRODUCTION STANDARD ASSEMBLIES
The Falk Equi-Poised motor mount is an all steel weldment Figure 2
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.
B9 D3
This modern design provides a simple means of tensioning (9 o’clock) (3 o'clock)
V-belts or chains with adjusting screws. Motor baseplates are
available from Factory pre-drilled for NEMA and IEC standard A6 C12
foot-mounted motors within the rated capacity of the drive. (6 o'clock) (12 o'clock)

Figure 1 -1 MOUNTS: -2 and -3 MOUNTS: Letter = Motor Mount Position

MOTOR
JAM NUTS 4, 5, 6, 7 Clock = Drive High-speed Shaft Position
BELT GUARD BASE PLATE WASHER
MOUNTING SLOTS 0.75"
ALL SIZES 4
5
JAM NUTS 1 OPTIONAL ASSEMBLY
6 1, 2, 3 2
ADJUSTING
SCREW 7 3 The motor mount may be mounted on the
high-speed shaft end of FLANGE MOUNTED
DRIVES – JF (also SCREW CONVEYOR
BASE PLATE
SUPPORT DRIVES – JSC) if clearance over the trough end
4 X BASE PLATE
SUPPORT NUT
permits) when increased motor mount clearance
4 X BASE PLATE is required at the driven machine. Consult
SUPPORT BOLT
Factory for SHAFT-MOUNTED DRIVES – JR.
4 X BASE PLATE
SUPPORT
LOCK WASHER

SUPPORT LEG
GUARDS
(ATTACHED TO
INPUT SIDE OF
DRIVE)
CAUTION: Consult applicable OSHA type
local and national safety codes guard when
SUPPORT LEG for proper guarding of rotating specified.
FASTENERS
members. Dimensions
to suit
Mounting slots located on the components.
motor base plate are provided
for installing a belt guard. Refer
-4 MOUNTS: ADAPTER PLATE to Appendix L for installation of
Falk V-Belt guards.
4 X ADAPTER PLATE BOLT WARNING: Remove all external loads from system before
4 X ADAPTER PLATE WASHER servicing drive or accessories.
4 X ADAPTER PLATE NUT
1. ATTACH BASE PLATE SUPPORT TO SUPPORT
LEGS — Loosely assemble support legs to the base
plate support as shown in Figure 1.
ASSEMBLY INSTRUCTIONS 2. ATTACH SUPPORT LEGS WITH BASE PLATE
From Figure 2, determine which assembly is required. SUPPORT TO DRIVE — To determine the number of
For minimum bearing loads on driven machine, minimum housing flange fasteners to be removed for a given
shaft deflection and the most economical belt selections, shaft center and drive size, refer to Table 3. Attach
use the 6 o’clock mounting position, high-speed shaft support legs to the input side of drive with the hex nuts
relative to the low-speed shaft, illustrated in Figure 1. The on output side of drive. Tighten support leg and base
motor/drive assembly can also be mounted in positions plate support fasteners to torque values specified in
shown in Figure 2. Always locate air vent at the top of Table 2.
horizontal drives. a. For Compact (C)
and Short (S)
TABLE 1 — Torque Arm Kit Clearance centers the
Dimensions support arms
ARM CUTOFF
OPTIONAL

Distance from Distance from may need to A6C

6.12

Output Shaft Bottom (Ref) be cut to allow

5107J-1-A6C 5.88 (6.12) clearance for a
5107J-1-A6S 5.88 (2.92) torque arm kit.
6.12

5115J-1-A6C 6.12 (6.12) See Table 1 for

5115J-1-A6S 6.12 (2.92)
dimensions.
Once cut, SUPPORT ARM
5115J-2-A6C 6.12 (6.12) CUTOFF DIMENSION
deburr the end WHEN USING
TORQUE ARM
5115J-2-A6S 6.12 (2.92) and touch up
5203J-1-A6C 8.00 (2.26) the paint.
5203J-2-A6C 8.00 (2.26)

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 Falk® Quadrive® Shaft Mounted Drives Model A • Appendix D
Sizes 5107-5315 (Page 37 of 52)

Motor Mount Installation

TABLE 2 — Motor Mount Fasteners & Torques lb-ft (Nm)
Support Leg to Support Leg Adapter Plate to -1 & -2 Adjusting
-3 Adjusting Screws -4 Adjusting Screws
Baseplate Support to Housing Baseplate Support Screws
DRIVE
SIZE Tightening Tightening Tightening Fastener Tightening Fastener Tightening Tightening
Fastener Size Fastener Size Fastener Size Fastener Size
Torque Torque Torque Size Torque Size Torque Torque
5107 .375-16UNC x 1.00 28 (38) .312-18UNC x 1.50 20 (26) ... ... .625-11UNC 137 (186) ... ... ... ...
5115 .375-16UNC x 1.00 28 (38) .312-18UNC x 1.50 20 (26) ... ... .625-11UNC 137 (186) ... ... ... ...
5203 .500-13UNC x 1.25 69 (94) .375-16UNC x 2.00 28 (38) ... ... .625-11UNC 137 (186) ... ... ... ...
5207 .500-13UNC x 1.25 69 (94) .500-13UNC x 2.25 69 (94) ... ... .625-11UNC 137 (186) .750-10UNC 108 (146) ... ...
5215 .625-11UNC x 1.50 137 (186) .500-13UNC x 2.25 69 (94) ... ... .625-11UNC 137 (186) .750-10UNC 108 (146) ... ...
5307 .750-10UNC x 1.75 245 (332) .500-13UNC x 2.50 69 (94) .625-11UNC x 1.50 60 (81) .625-11UNC 137 (186) .750-10UNC 108 (146) 1.000-8UNC x 8.00 180 (244)
5315 .750-10UNC x 1.75 245 (332) .500-13UNC x 2.50 69 (94) .625-11UNC x 1.50 60 (81) .625-11UNC 137 (186) .750-10UNC 108 (146) 1.000-8UNC x 8.00 180 (244)

3. Loosely install adjusting screws, washers (for flat-head 5. MOUNT MOTOR — Position motor on motor base
socket cap screws only) and jam nuts (except #3 and plate so that all mounting holes are in alignment. Install
#7) on to the motor base plate per Figure 1. Do not and tighten motor fasteners.
tighten adjusting bolts until step 4. 6. SPROCKET, PULLEY OR SHEAVE CONNECTION —
NOTE: If your motor base plate uses two 82 degree Mount power take-offs as close to drive and motor
flat-head socket cap screws, make sure to install the housing as possible to avoid undue bearing load
washer between motor base plate and first jam nut as and shaft deflection. Align the high-speed shaft of
shown in Figure 1, otherwise motor base plate may drive square and parallel with motor shaft by placing
be loose between the flathead cap screw and motor a straightedge across the face of the sprockets or
base plate. sheaves as illustrated in Figure 4. Check horizontal
4. ATTACH MOTOR BASE PLATE TO BASE PLATE shaft alignment by placing one leg of a square against
SUPPORT — Install motor base plate onto base the face of the sheave or sprocket with the spirit level
plate support, install jam nuts 3 and 7 per Figure 1. on the horizontal leg of the square.
Set motor plate to desired height and torque all jam
nuts per Table 2. After jam nuts are tightened make RIGHT WRONG
Figure 4
sure motor base plate is fully secured to base plate
support.

Figure 3

L
S M LONG GEAR DRIVE WALL
SHORT MEDIUM CENTERS
CENTERS CENTERS

LEVEL
SQUARE AND
TABLE 3 — Support Leg Fastener Quantity PARALLEL
(Per Side)
Drive Size
A6 Shaft
Centers 5307 &
5107 5115 5203 5207 5215 Adjustment of the belt or chain is accomplished
5315
by turning adjusting screws evenly. DO NOT over-
Compact 3 3 4 ... ... ...
tighten belts or chains. Over-tightening belts or chains
Short 3 3 4 4 4 6 reduces belt/chain and bearing life. When the required
Medium 3 3 3 3 3 5 tension is reached, tighten adjusting screw jam nuts
Long 2 2 2 2 2 4 to torques listed in Table 2. Adjust chain tension to
A3 & A9 Shaft manufacturer’s specifications. Adjust belts as follows:
Centers The ideal belt tension is the lowest tension at which
Compact 3 3 3 ... ... ... the belt will not slip under peak load conditions. Check
Short 3 3 3 3 3 5 belt tension frequently during the first 24 to 48 hours of
Medium 3 3 3 2 2 4
run-in operation. Keep belts free from foreign material
which may cause slippage. Inspect the V-belt drive
Long 2 2 2 ... ... 3 periodically; re-tighten belts if they are slipping.

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Appendix E • Falk® Quadrive® Shaft Mounted Drives Model A
(Page 38 of 52) Sizes 5107-5315

Vertical Standpipe Installation

INTRODUCTION 6. Scribe Dimensions X + A and X + B on the dipstick as
illustrated in Figure 1. Make measurements from the
The following instructions apply to the installation of felt pad in the dipstick cap.
standpipe kits to standard drives mounted for vertical
operation (high-speed shaft up or down). Drawings are 7. Lightly chisel permanent oil level marks on the scribed
representative of this series of drives and may not agree in lines and cut the dipstick to the length marked. File
exact detail with all drive sizes. end of dipstick smooth.
8. Install magnetic drain plug furnished in oil drain
location.
HIGH-SPEED SHAFT DOWN — FIGURE 1
9. Remove the oil filler plug. Add oil until the oil level
1. After installing the drive per the Owners Manual reaches the “Full” mark on the dipstick. Coat the filler
installation instructions, determine which of the lower plug (not vented) with Permatex #3 or equivalent
side plug locations on the drive will provide the best sealant and replace it.
location for the standpipe, observing clearance
10. Filler plug must always be removed to relieve
required to remove dipstick (Dimension D, Table 1).
entrapped air before checking oil level.
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. Re- HIGH-SPEED SHAFT UP — FIGURE 2
coat pipe plug threads with Permatex #3 or equivalent
sealant before reinstalling. 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
TABLE 1 — Dimensions – Inches (mm) best location for the standpipe, observing clearance
DRIVE SIZE A B C D required to remove dipstick (Dimension D, Table 1).
Discard the air vent. When the air vent location is not
5107 0.90 (23) 1.10 (28) 1.60 (41) 19.2 (488) used for the standpipe, relocate the pipe plug from the
5115 0.90 (23) 1.10 (28) 1.60 (41) 18.3 (465)
5203 selected standpipe location to the air vent location. Re-
1.08 (27) 1.28 (33) 1.78 (45) 18.2 (462)
coat pipe plug threads with Permatex #3 or equivalent
5207 1.14 (29) 1.34 (34) 1.84 (47) 20.4 (518)
5215 1.54 (39) 1.74 (44) 2.24 (57) 22.1 (561) sealant before reinstalling.
5307 1.54 (39) 1.84 (47) 2.34 (59) 23.7 (602)
5315 1.70 (43) 2.20 (56) 2.70 (69) 23.1 (587) Figure 2 VENTED FILLER PLUG

2. Coat all pipe threads of kitted parts with Permatex #3 OIL LEVEL
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. USE REDUCING BUSHING
FOR SIZES 5107 THRU 5207
Figure 1 SCALE
DIPSTICK
D CAP
STRAIGHT
EDGE CLEARANCE OIL DRAIN
FO R DIPSTICK
FILLER REMOVAL
X
PLUG
FELT X+ A
PAD 2. Coat all pipe threads of kitted parts with Permatex #3
X+B
or equivalent sealant.
X+C 3. Assemble kitted parts to drive as illustrated in Figure
OIL FULL
LEVEL { 2 and then secure the standpipe with an external
MARKS LOW support to maintain its vertical position.
USEREDUCING
OIL DRAIN BUSHING FOR
FILE SMOOTH 4. See Figure 1 and follow steps 4 thru 7.
SIZES 5107 THRU 5207
5. Install magnetic drain plug furnished in oil drain
location.
4. Carefully measure Dimension “X” as illustrated in Figure 1. 6. Remove one of the three oil level plugs. Add oil
5. From Table 1: through the standpipe until the oil level reaches
the plug hole. Coat the plug with Permatex #3 or
X + A equals oil level “Full” mark.
equivalent sealant and replace it. Be sure to use only
X + B equals oil level “Low” mark. the vented filler plug in the standpipe.
X + C equals dipstick length.

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 Falk® Quadrive® Shaft Mounted Drives Model A • Owners Manual
Sizes 5107-5315 (Page 39 of 52)

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Appendix F • Falk® Quadrive® Shaft Mounted Drives Model A
(Page 40 of 52) Sizes 5107-5315

Modifications for Non-Standard Mounting Positions

INSTRUCTIONS Remove all pipe plugs and coat them and the added parts, with
Permatex #3 or equivalent to prevent leakage. Install parts as
For non-standard mountings, modify drives as illustrated
illustrated to suit the mounting position. The air vent must be in
below and on Page 38 to assure satisfactory lubrication.
the top of the drive or in the kit standpipe. Fill drives with oil to the
For applications that exceed the limits shown, drives that
level indicated by the letter “L” in the following drawings.
are both rotated AND tilted and drives with backstops, STANDARD DRIVE MOUNTING
consult Factory.
LIMITS
CAUTION: Inadequate lubrication will cause damage.
The standard drive rotation limits from the
When replacing a pipe plug (P) with a street elbow (E), basic 3, 6, 9 & 12 o’clock mounting positions
insert the plug in the elbow (E/P). When replacing a pipe are given in Section I, Page 4. For higher
plug (P) with a street elbow (E), pipe nipple (N) and a pipe limits, follow the instructions at the left and the
cap (C), discard the pipe plug. Kits consist of parts for an drawings below (6 o’clock illustrated).
oil expansion chamber. Pipe fittings and kits tabulated on CODE
CW CCW
Page 35 are available from Rexnord. Pipe fittings may also
B — Bushing N — Nipple
be purchased locally. Use galvanized pipe fittings.
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 5 to 20° CCW Rotation – Sizes 5203 thru 5315
10 to 20° CW Rotation – Sizes 5203 thru 5315 10 to 20° CCW Rotation – Sizes 5107 & 5115
3 o’clock — CW Rotation 3 o’Clock — CCW Rotation

L L L
L
L
L

5107 = STD 5115 = .375 E/P 5203 & 5207 = KIT 0786775 5107 = KIT 0738540 5115 = STD 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
6 o’Clock — CW Rotation 6 o’Clock — CCW Rotation 5315 = .500 E/C & .500 X 2.50N

L L L
L L

5107 = STD 5115 = .375 E/P 5203 thru 5315 = STD 5107 & 5115 = 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 o’Clock — CW Rotation 9 o’Clock — CCW Rotation

L L
L
L L

5-15° 16-20°
5107 = 5-12° STD 5203 & 5207 = KIT 0786775 5107 = .375 E/C & 5115 = KIT 0786775 5203 = .375 E/C & .375 X 1.00N 1.50N
5107 = 13-20° .375 E/P 5215 thru 5315 = KIT 0786776 .375 X 3.00N 5207 = .375 E/C & .375 X 1.00N 1.50N
5115 = .375 E/P 5215 = .500 E/C & .500 X 1.12N 1.50N
5307 = .500 E/C & .500 X 1.50N 2.00N
12 o’Clock — CCW Rotation 5315 = .500 E/C & .500 X 1.50N 2.00N
12 o’Clock — CW Rotation

L
L
L
L
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
5107 = .375 E/P 5115 = .375 E/P 5203 & 5207 = KIT 0786775 5107 & 5115 = KIT 0738540 5315 = .500 E/C & .500 X 2.50N
5215 thru 5315 = KIT 0786776

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 Falk® Quadrive® Shaft Mounted Drives Model A • Appendix F
Sizes 5107-5315 (Page 41 of 52)

Modifications for Non-Standard Mounting Positions

STANDARD DRIVE Standard Pipe Fittings  — Inches

MOUNTING LIMITS
.375-18 NPT Falk No. .500-14 NPT Falk No.
The standard drive incline limits from
the basic 3, 6, 9 & 12 o’clock mounting .375 Street Elbow 0915252 .500 Street Elbow 0915251
.375 Cap 0914802 .500 Cap 0914803
positions are given in Section I, Page 4.
.375 x 1 Nipple 0915724 .500 x 1.12 Nipple 0915734
For higher limits, follow the instructions .375 x 1.5 Nipple 0915725 .500 x 1.5 Nipple 0915735
UP on Page 38 and the drawings below (6 .375 x 2 Nipple 0915722 .500 x 2 Nipple 0915736
DOWN o’clock illustrated). 0915727 0915723
.375 x 3 Nipple .500 x 2.5 Nipple
.500 x 3 Nipple 0915737
CODE .500 x 4 Nipple 0915739
C — Cap N — Nipple c Kits: Falk Nos. 0786775 & 0786776, oil expansion chamber parts. All
pipe fittings are galvanized.
E — Street Elbow P — Pipe Plug
L — Oil Level STD — No Modifications

HORIZONTAL DRIVE MODIFICATIONS FOR INCLINED H.S. SHAFT

H.S. Shaft Inclined 20 to 30° Up H.S. Shaft Inclined 5 to 30° Down
5107 = 5-25° .375 E/P
3 o’Clock — H,S,S Up 3 o’Clock — H,S,S Down 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
L 5207 = 5-15° .375 E/P
5107 THRU 5315 = STD 5207 = 16-30° .375 E/C & .375 X 2.00N
L
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
6 o’clock — H,S,S Up 6 o’Clock — H,S,S Down
5107 = .375 E/P
5115 = .375 E/C & .375 X 2.00N
5203 = .375 E/C & .375 X 1.50N
L 5107 THRU 5315 = STD 5207 = .375 E/C & .375 X 2.00N
L
5215 = .500 E/C & .500 X 2.50N
✱ 5307 = .500 E/C & .500 X 2.50N
5315 = .500 E/C & .500 X 2.50N

5107 = 5-15° STD

9 o’clock — H,S,S Up 9 o’Clock — H,S,S Down 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
L 5203 = 21-30° .375 E/C, .375 X 1.50N & KIT 0786775
5107 THRU 5307 = STD
L 5207 = 5-20° .375 E/C
5315 = KIT 0786776 ✱ 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
12 o’Clock — H,S,S Up 12 o’Clock — H,S,S Down 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
5107 THRU 5315 = STD L 5115 = 16-30° .375 E/C, .375 X 2.00N & KIT 0786775
L
✱ 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

4 This oil level applies when only a street elbow with a pipe plug is used.

L — Always locate at high side plug.

KIT — Install at standard air vent location.

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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 JF & JSC — Retaining Rings for Thrust
DRIVE SIZE Manufacturer Part Number Plate Kits
5107 Truarc N5000-237 DRIVE SIZE Manufacturer Part Number
5115 Truarc N5000-312 5107 Truarc N5000-165
5203 Truarc N5000-334 5115 Eaton IN225
5207 Eaton IN375 5203 Eaton IN244
5215 Truarc N5000-462 5207 Eaton IN281
5307 Eaton IN500 5215 Eaton IN334
5315 Truarc N5000-575 5307 Eaton IN375
5315 Eaton IN433

Tooth Combinations for Vibration Analysis

Type J05 — Tooth Combinations Type J09 — Tooth Combinations

DRIVE Exact Pinion Gear Input Output
SIZE Ratio Ref. #3A3 Ref. #4A4 DRIVE Exact
SIZE Ratio Pinion Gear Pinion Gear
5107 5.077 13 66 Ref. #1A3 Ref. #1A4 Ref. #2A Ref. #4A4
5115 5.053 19 96
5203 5.071 14 71 5107 9.462 22 41 13 66
5115 9.357 27 50 19 96
5207 5.077 13 66 5203 9.179 21 38 14 71
5215 4.923 13 64
5307 4.857 14 68 5207 9.492 23 43 13 66
5315 4.857 14 68 5215 8.997 29 53 13 64
5307 9.131 25 47 14 68
5315 9.131 25 47 14 68

Type J14 — Tooth Combinations Type J25 — Tooth Combinations

Input Output Input Output
DRIVE Exact DRIVE Exact
SIZE Ratio Pinion Gear Pinion Gear SIZE Ratio Pinion Gear Pinion Gear
Ref. #1A3 Ref. #1A4 Ref. #2A3 Ref. #4A4 Ref. #1A3 Ref. #1A4 Ref. #2A3 Ref. #4A4
5107 14.43 19 54 13 66 5107 25.81 12 61 13 66
5115 13.95 21 58 19 96 5115 24.87 13 64 19 96
5203 14.45 20 57 14 71 5203 26.94 16 85 14 71
5207 14.47 20 57 13 66 5207 24.99 13 64 13 66
5215 13.60 21 58 13 64 5215 24.94 15 76 13 64
5307 14.03 18 52 14 68 5307 25.26 15 78 14 68
5315 13.91 22 63 14 68 5315 25.26 15 78 14 68

Seal Housing Lip Seals for Types JSC

Type JSC — Seal Housing Lip Seals Accessory
DRIVE SIZE Falk Part No. Manufacturer’s Part No.
5107 2905318 Chicago Rawhide 17271
5115 0912859 National 470565
5203 2911847 Chicago Rawhide 26153
5207 0912835 Chicago Rawhide 29865
5215 2911957 Chicago Rawhide 34861
5307 0912741 Chicago Rawhide 34886
5315 0912741 Chicago Rawhide 34886

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 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 LB LC  Key
D LA
DRIVE L +.000, – .010 +.040, – .000 T
+.000, – .005 DA ±.030 LD LE MD  S
SIZE W ±.010 (+0,00, – (+1.02, – Min W H L
(+0.00, – 0.13, (±0.76)
(±0.25) 0.25) 0.00)

5107⑤ .375 (9.53) 2.875 (73.02) 1.614 (40.996) 1.750 (44.45) .437 (11.10) 1.329 (33.76) 3.679 (93.45) 1.50 (38.1) 1.50 (38.1) 1.07 (27.2) .500-13 2.00 (50.8) .375 .375 2.50
5115 .500 (12.70) 3.250 (82.55) 2.173 (55.194) 2.357 (59.87) .500 (12.70) 1.902 (48.31) 5.656 (143.66) 2.72 (69.1) 1.50 (38.1) 1.16 (29.46) .500-13 2.00 (50.8) .500 .375 2.75
5203 .500 (12.70) 3.750 (95.25) 2.425 (61.595) 2.620 (66.55) .500 (12.70) 2.153 (54.69) 5.286 (134.26) 2.13 (54.1) 1.50 (38.1) 1.10 (27.9) .625-11 2.00 (50.8) .500 .375 3.25

5207 .625 (15.88) 4.875 (123.82) 2.725 (69.215) 2.920 (74.17) .625 (15.88) 2.416 (61.37) 6.218 (157.94) 3.10 (78.7) 2.00 (50.8) 1.11 (28.2) .625-11 2.00 (50.8) .625 .438 4.25
5215 .750 (19.05) 4.250 (107.95) 3.258 (82.753) 3.500 (88.90) .750 (19.05) 2.923 (74.24) 7.616 (193.45) 3.75 (95.3) 2.00 (50.8) 1.19 (30.2) .875-9 2.50 (63.5) .750 .500 3.50
5307 .875 (22.23) 5.875 (149.22) 3.878 (98.501) 4.100 (104.14) .875 (22.22) 3.413 (86.69) 8.008 (203.40) 4.46 (113.3) 2.04 (51.8) 1.27 (32.2) 1.000-8 2.75 (69.8) .875 .625 5.00
5315 1.000 (25.40) 6.000 (152.40) 4.433 (112.598) 4.664 (118.47) 1.000 (25.40) 3.871 (98.32) 8.398 (213.31) 4.75 (120.7) 2.00 (50.8) 1.27 (32.2) 1.000-8 2.75 (69.8) 1.000 .750 5.00

c 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.
z Dimension “MD” will vary slightly depending on degree of axial compression during installation and manufacturing tolerances.
4 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).

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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 Attach the drive to the mounting surface with fasteners (not
flange-mounted 5107-5315JF drive is to be used and the provided). Refer to Table 1 for fastener size and tightening
manufacture of a tapered drive shaft is not feasible. For torque. Assemble the thrust plate and retaining ring into
JF tapered drive shaft recommendations, see Appendix the counterbore in the hollow shaft. Insert the thrust plate
H. Use this appendix to retrofit existing applications or for fastener through the thrust plate and thread into the drive
outfitting new installations. Parts required are the Basic shaft end. Tighten to the torque given in Table 2. Install all
drive, TA Taper bushing and a thrust plate kit. covers and guards.
This appendix will allow the use of a straight drive shaft REMOVAL PROCEDURE — Remove low-speed shaft
with the tapered bushing (without spanner nut) on flange- input end cover. Remove the thrust plate fastener, retaining
mounted applications. Provided are dimensions (Table ring and thrust plate from the hollow shaft. Refer to Table
4) for shaft recommendations and instructions for the 3 and select a backing bolt and flat washer and install
installation and removal of the assembly. All bushing bore them into the drive shaft as illustrated in Figure 1. The
sizes, which are available in the standard Quadrive, are head of the backing bolt provides a working surface for
possible with this setup. the removal bolt. Reinsert the thrust plate and retaining
Drives are provided with tapped holes in the output face of ring into the hollow shaft and select a removal bolt from
the housing along with a female register to allow mounting Table 3. Thread the removal bolt into the thrust plate until
to the driven equipment. JF drives are mounted to the it contacts the backing bolt head. Tighten the removal bolt
equipment without the use of an adapter flange. Optional to the torque indicated in Table 3 (if the thrust plate rotates
adapter flanges are available, consult the Factory. 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
FIGURE 2 — The hollow shaft of the drive has a tapered prevent rotation of the plate). After torquing the bolt, as
bore which accepts the tapered bushing. When the instructed, strike the bolt sharply with a hammer and re-
bushing is drawn into the taper, a clamping force is applied torque the bolt if separation of the drive from the shaft did
to the drive shaft. The drive shaft is drawn into the hollow not occur. Repeat this procedure, re-torquing the bolt after
shaft via a fastener in the thrust plate. The bushing seats each blow, until separation occurs.
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 Figure 1
BACKING BOLT TAPPED HOLE
of the drive. The retaining ring in the drive shaft assures IN DRIVE SHAFT
that the bushing will be removed along with the shaft.
REMOVAL
DRIVE SHAFT RECOMMENDATIONS — The BOLT
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 DRIVE SHAFT
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 THRUST RETAINING BUSHING
PLATE RING
be a welded collar or an integral step. SET COLLARS
ARE NOT ACCEPTABLE. A retaining ring may be used, RETAINING
in the driven shaft, to provide the shoulder, but stress RING
concentrations occur at the groove and therefore shaft HOLLOW
stresses must be checked. The second major feature on SHAFT
the shaft is the retaining ring groove in the shaft end. This FLAT WASHER
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. TABLE 1 — JF Drive – Foundation Fastener
WARNING: Lock out power source and remove all external & Tightening Torque
loads from system before servicing drive or accessories. (Non-Lubricated Fasteners)
INSTALLATION PROCEDURE — With the drive shaft Min. Fastener
Max Tightening
manufactured per the recommendations shown, and the DRIVE Fastener Size Torque Engagement Into
bushing selected for the proper shaft diameter, remove SIZE & Grade lb-ft (Nm) Drive Housing
and discard the retaining ring and spanner nut from the Inch (mm)
bushing assembly. 5107 .500-13UNC, GR. 5 69 (94) .76 (19.3)
5115 .625-11UNC, GR. 5 137 (186) .94 (23.9)
Slide the bushing (flange end first) onto the drive shaft until 5203 .750-10UNC, GR. 5 245 (332) .76 (19.3)
it contacts the shoulder on the shaft. Insert the key through
5207 .875- 9UNC, GR. 5 380 (515) .88 (22.4)
the bushing and into the drive shaft keyway. Install the 5215 1.000- 8UNC, GR. 5 567 (769) 1.00 (25.4)
retaining ring into the groove in the drive shaft. Bring the 5307 1.000- 8UNC, GR. 8 792 (1074) 1.24 (31.5)
drive into position, line-up the hollow shaft keyway with the 5315 1.000- 8UNC, GR. 8 792 (1074) 1.24 (31.5)
key, and slide the bushing and drive shaft into the hollow
shaft bore.

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 Falk® Quadrive® Shaft Mounted Drives Model A • Appendix J
Sizes 5107-5315 (Page 45 of 52)

Drive Shaft Recomendations Using TA Taper Bushing

MOUNTING
Figure 1 SURFACE

FURNISHED
BY CUSTOMER W (Keyway) B
A

H (Keyway) L (Keyway)
DB
D
DA
F 0.010” (0.25 mm) R MAX.
IN GROOVE CORNERS
G
THRUST .06” (1.5 mm) RADIUS
PLATE 1-S DIA. UNC TAPPED HOLE
FASTENER T-DEEP

C
MOUNTING
SURFACE

TABLE 2 — Thrust Plate Fastener Data  TABLE 3 — Removal & Backing Bolt Size
(Non-Lubricated Fasteners) and Tightening Torque
DRIVE Max Tightening Min Thread Depth Backing Bolt
Fastener Size & Grade DRIVE Removal Bolt Size & Max Tightening
SIZE Torque lb-ft (Nm) Inches (mm) Size & Max
SIZE Min Length – Inches Torque lb-ft (Nm) Length – Inches
5107 .500-13UNC x 3.50, GR.8 92 (125) 2.00 (50.8)
5115 .500-13UNC x 4.00, GR.8 92 (125) 2.00 (50.8) 5107 .625-11UNC x 1.75 133 (180) .500-13UNC x 1.25
5203 .625-11UNC x 3.50, GR.8 183 (248) 2.00 (50.8) 5115 .625-11UNC x 1.75 133 (180) .500-13UNC x 1.25
5203 .750-10UNC x 2.00 242 (328) .625-11UNC x 1.75
5207 .625-11UNC x 3.50, GR.8 183 (248) 2.00 (50.8)
5215 .875- 9UNC x 5.00, GR.8 533 (723) 2.50 (63.5) 5207 .750-10UNC x 2.00 242 (328) .625-11UNC x 1.75
5307 1.000- 8UNC x 5.00, GR.5 567 (769) 2.50 (63.5) 5215 1.000- 8UNC x 2.50 567 (769) .875- 9UNC x 2.25
5315 1.000- 8UNC x 5.00, GR.8 792 (1074) 2.50 (63.5) 5307 1.125- 7UNC x 3.00 742 (1006) 1.000- 8UNC x 2.50
5315 1.125- 7UNC x 3.00 742 (1006) 1.000- 8UNC x 2.50
c Fasteners may be hex socket head or hex head except for size 5307,
which must be a hex head to clear input end cover.

TABLE 4 — Dimensions for Largest Bore Bushing – Inches (mm) 

Retaining Ring ♣ Keyway ♥
Thrust
Thrust A B
DRIVE Plate ± 0.010 DA DB Groove Spir O Lox T
Plate ± 0.030 C D L S
SIZE Part  Min W H Min
Kit  (±0.250) (±0.75) Mfg Max Min
No. F G No. O.D
4.780 5.000 -1.356 (-34.4) 2.500 1.750 1.295 0.056 3.563 2.00
5107 TP4107JF 0778773 (121.41) (127.00) -1.606 (-40.8) (63.50) 1.4375 (44.45) 1.287 0.060 RSN-137 1.500 0.375 0.1875 (90.50) 0.500-13 (50.8)

5.330 5.500 -1.528 (-38.8) 3.250 2.250 1.735 0.068 4.000 2.00
5115 TP4115JF 0778774 (135.38) (139.70) -1.794 (-45.6) (82.55 1.9375 (57.15) 1.725 0.072 RST-181 2.000 0.500 0.2500 (101.60) 0.500-13 (50.8)

5.310 5.625 -1.634 (-41.5) 3.500 2.500 1.952 0.086 4.625 2.00
5203 TP4203JF 0778775 (134.87) (142.88) -1.921 (-48.8) (88.90) 2.1875 (63.50) 1.940 0.091 RSN-206 2.250 0.500 0.2500 (117.48) 0.625-11 (50.8)

5.890 6.250 -1.557 (-39.6) 4.000 2.750 2.290 0.056 5.625 2.00
5207 TP4207JF 0778776 (149.61) (158.75) -1.885 (-47.9) (101.60) 2.4375 (69.85) 2.278 0.060 RS-236 2.500 0.625 0.3125 (142.88) 0.625-11 (50.8)

6.860 7.125 -1.755 (-44.6) 4.750 3.250 2.728 0.056 5.875 2.50
5215 TP4215JF 0778777 (174.24) (180.98) -2.082 (-52.9) (120.65) 2.9375 (82.55) 2.716 0.060 RS-281 3.062 0.750 0.3750 (149.22) 0.875-9 (63.5)

7.170 7.500 -1.843 (-46.8) 5.125 3.750 3.172 0.103 6.750 2.50
5307 TP4307JF 0778778 (182.12) (190.50) -2.175 (-55.2) (130.18) 3.4375 (95.25) 3.160 0.108 RSN-334 3.625 0.875 0.4375 (171.45) 1.000-8 (63.5)

7.700 8.000 -1.840 (-46.7) 6.000 4.250 3.701 0.120 7.062 2.50
5315 TP4315JF 0778779 (195.58) (203.20) -2.175 (-55.2) (152.40) 3.9375 (107.95) 3.690 0.125 RST-387 4.125 1.000 0.5000 (179.37) 1.000-8 (63.5)

c 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.
z The D dimension is the recommended minimum bore which clears the TA Taper bushing flange.
4  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.
w Smalley retaining rings may be used instead of Spir O Lox by substituting WS for RS. WST for RST or WSM for RSN.
y 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

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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 in the drive shaft. Line up the keyway in the drive hollow
screw conveyor 5107 - 5315JSC drive is to be used and the shaft with the key in the drive shaft and slide shaft/bushing
following conditions exist: Falk standard or 316 stainless steel assembly into the hollow shaft. Attach the seal housing to
JSC tapered drive shafts can not be used due to special the drive with the fasteners provided.
extension dimensions or materials; or manufacturing a Tighten fasteners to torque given in Table 1. Assemble the
special tapered drive shaft is not feasible. Use this appendix thrust plate and retaining ring into the counterbore in the
to retrofit existing applications or for outfitting new installations hollow shaft. Insert the thrust plate fastener through the
where the above conditions warrant. For tapered shaft thrust plate and thread into the drive shaft end. Tighten to
recommendations, see Appendix H. the torque given in Table 2. Install all covers and guards.
This appendix will allow the use of a straight (non-tapered) REMOVAL PROCEDURE — Remove low-speed shaft input
drive shaft with a special bushing conversion kit on screw end cover. Remove the thrust plate fastener, retaining ring and
conveyor applications. This kit provides one bushing bore per thrust plate from the hollow shaft. Refer to Table 3 and select a
drive size as shown in Table 4. Provided in this appendix are backing bolt and flat washer and install them into the drive shaft
dimensions for drive shaft recommendations and instructions as illustrated in Figure 1. The head of the backing bolt provides
for the installation and removal of the assembly. a working surface for the removal bolt. Reinsert the thrust plate
FIGURE 2 — The hollow shaft of the drive has a tapered and retaining ring into the hollow shaft and select a removal bolt
bore which accepts the tapered bushing. When the from Table 3. Thread the removal bolt into the thrust plate until it
bushing is drawn into the taper, a clamping force is applied contacts the backing bolt head. Tighten the removal bolt to the
to the drive shaft. The drive shaft is drawn into the hollow torque indicated in Table 3 (if the thrust plate rotates in the shaft,
shaft via a fastener in the thrust plate. The bushing seats align the slot in the plate with the hollow shaft keyway and insert
against a shoulder on the drive shaft and is drawn into the a screwdriver or piece of key stock to prevent rotation of the
drive with the shaft. Removal is accomplished by using a plate). After torquing the bolt, as instructed, strike the bolt sharply
jackscrew in the thrust plate and forcing the drive shaft out with a hammer and re-torque the bolt if separation of the drive
of the drive. The retaining ring in the drive shaft assures from the shaft did not occur. Repeat this procedure, re-torquing
that the bushing will be removed along with the shaft. the bolt after each blow, until separation occurs.
The packing gland sealing option (sizes 5107-5315) is BACKING BOLT TAPPED HOLE
usable with the bushing kit, but the clamp ring must be Figure 1 IN DRIVE SHAFT

assembled from the extension end of the drive shaft on REMOVAL

BOLT
sizes 5307 and 5315.
DRIVE SHAFT
DRIVE SHAFT RECOMMENDATIONS — The
recommendations for the drive shaft consist of two major THRUST RETAINING BUSHING
features. The first is the shoulder which must be provided PLATE RING

in the location shown in Figure 2. This shoulder provides RETAINING

RING
the backing necessary to draw the bushing into the taper. A HOLLOW
SHAFT
permanently fixed shoulder must be provided in order for this FLAT WASHER
design to be effective. The shoulder may be a welded collar
or an integral step. SET COLLARS ARE NOT ACCEPTABLE. TABLE 1 — Seal Housing Fastener Tightening
A retaining ring may be used in the drive shaft, to provide the Torque (Non-Lubricated Fasteners)
shoulder, but stress concentrations can occur at the groove DRIVE Max Tightening
and therefore shaft stresses must be checked. The second Fastener Size
SIZE Torque lb-ft (Nm)
major feature on the shaft is the retaining ring groove in the
5107 .500-13UNC 69 (94)
shaft end. This feature is recommended to ensure positive 5115 .625-11UNC 137 (186)
removal of the bushing when the drive shaft is removed from 5203 .750-10UNC 245 (332)
the drive. The threaded hole in the end of the drive shaft 5207 .875- 9UNC 380 (515)
accepts the thrust plate fastener. 5215 1.000- 8UNC 567 (769)
WARNING: Lock out power source and remove all external 5307 1.000- 8UNC 792 (1074)
5315 1.000- 8UNC 792 (1074)
loads from system before servicing drive or accessories.
INSTALLATION PROCEDURE — With the shaft manufactured
per the recommendations shown, proceed as follows: TABLE 2 — Thrust Plate Fastener Data 
(Non-Lubricated Fasteners)
5107-5215JSC — The seal housing may be assembled to
the drive before or after the drive shaft is installed into the DRIVE Fastener Grade Max Tightening Min Thread Depth
drive, depending on the shaft extension diameter. SIZE & Size Torque lb-ft (Nm) Inches (mm)

5307-5315JSC — The seal housing must be assembled 5107 .500-13UNC x 3.50, GR.8 92 (125) 2.00 (50.8)
5115 .500-13UNC x 4.00, GR.8 92 (125) 2.00 (50.8)
over the drive shaft from the extension end of the shaft, or 5203 .625-11UNC x 3.50, GR.8 183 (248) 2.00 (50.8)
the shaft shoulder must be fixed in position after the seal
housing is assembled over the drive shaft (see Figure 2). 5207 .625-11UNC x 3.50, GR.8 183 (248) 2.00 (50.8)
5215 .875- 9UNC x 5.00, GR.8 533 (723) 2.50 (63.5)
ALL JSC DRIVES — Slide the bushing (large end first) 5307 1.000- 8UNC x 5.00, GR.5 567 (769) 2.50 (63.5)
onto the drive shaft until it contacts the shoulder on the 5315 1.000- 8UNC x 5.00, GR.8 792 (1074) 2.50 (63.5)
shaft. Insert the key through the bushing and into the c Fasteners may be hex socket head or hex head except for size 5307,
drive shaft keyway. Install the retaining ring into the groove which must be a hex head to clear input end cover.

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 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
MOUNTING SURFACE
SURFACE

U
MOUNTING
MOUNTING SURFACE
THRUST SURFACE THRUST
PLATE PLATE
FASTENER FASTENER
A C
C

W (Keyway) B
TABLE 3 — Removal & Backing Bolt Size A
and Tightening Torque
H (Keyway) L (Keyway)
DRIVE Removal Bolt Size & Max Tightening Backing Bolt Size & DB
SIZE Min Length – Inches Torque lb-ft (Nm) Max Length – Inches DA
F 0.010” (0.25 mm) R MAX.
5107 .625-11UNC x 1.75 133 (180) .500-13UNC x 1.25 IN GROOVE CORNERS
5115 .625-11UNC x 1.75 133 (180) .500-13UNC x 1.25
G
5203 .750-10UNC x 2.00 242 (328) .625-11UNC x 1.75
1-S DIA. UNC TAPPED HOLE .06” (1.5 mm) RADIUS
5207 .750-10UNC x 2.00 242 (328) .625-11UNC x 1.75 T-DEEP
5215 1.000- 8UNC x 2.50 567 (769) .875- 9UNC x 2.25
5307 1.125- 7UNC x 3.00 742 (1006) 1.000- 8UNC x 2.50
5315 1.125- 7UNC x 3.00 742 (1006) 1.000- 8UNC x 2.50

TABLE 4 — Dimensions – Inches (mm)

Taper (TCB) Retaining Ring  Keyway ♣ Weld/Integral
A B DB 
Conversion Kit T Flange
± 0.010 ± 0.030 C DA  +0.000, - 0.003 Groove Mfg Max L S
Bushing Part W H Min
(± 0.25) (± 0.75) (+0.00, - 0.08) No. O.D. Min
Kit  No. F G U V

TCB5107J- 4.780 5.000 2.625 (66.68) 1.750 1.295 0.056 Spir O Lox 3.563 2.00
0766041 1.4375 1.500 0.375 0.1875 0.500-13 ... ...
1.438 (121.41) (127.00) 2.414 (61.32) (44.45) 1.287 0.060 RSN-137 (90.50) (50.8)

TCB5115J- 5.330 5.500 2.452 (62.28) 2.375 1.735 0.068 Spir O Lox 4.000 2.00
0766042 1.9375 2.000 0.500 0.2500 0.500-13 ... ...
1.938 (135.38) (139.70) 2.226 (56.54 (60.33) 1.725 0.072 RST-181 (101.60) (50.8)

TCB5203J- 5.310 5.625 2.346 (59.59) 2.625 1.952 0.086 Spir O Lox 4.625 2.00
0766043 2.1875 2.250 0.500 0.2500 0.625-11 ... ...
2.188 (134.87) (142.88) 2.099 (53.31) (66.68) 1.940 0.091 RSN-206 (117.48) (50.8)

TCB5207J- 5.890 6.250 2.548 (64.72) 3.000 2.290 0.056 Spir O Lox 5.625 2.00
0766044 2.4375 2.500 0.625 0.3125 0.625-11 ... ...
2.438 (149.61) (158.75) 2.260 (57.40) (76.20) 2.278 0.060 RS-236 (142.88) (50.8)

TCB5215J- 6.860 7.125 2.475 (62.87) 3.500 2.728 0.056 Spir O Lox 5.875 2.50
0766045 2.9375 3.062 0.750 0.3750 0.875-9 ... ...
2.938 (174.24) (180.98) 2.188 (55.58) (88.90) 2.716 0.060 RS-281 (149.22) (63.5)

TCB5307J- 6.530 6.860 3.527 (89.59) 3.500 3.172 0.103 Spir O Lox 6.750 2.50 0.375 ♥ 4.250
0766046 3.4375 3.625 0.875 0.4375 1.000-8
3.438 (165.86) (174.24) 3.235 (82.17) (88.90) 3.160 0.108 RSN-334 (171.45) (63.5) (9.52) (107.95)

TCB5315J- 7.030 8.500 3.560 (90.42) 3.500 3.263 0.103 Spir O Lox 8.250 2.50 0.375 ♥ 4.250
0785785 3.4375 ... 0.875 0.4375 1.000-8
3.438 (178.56) (215.90) 3.266 (82.96) (88.90) 3.251 0.108 RSN-343 (209.55) (63.5) (9.52) (107.95)

c 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”.
z If a lip type seal is used, a 32rms finish is recommended.
4 Smalley retaining rings may be used instead of Spir O Lox by substituting WS for RS, WST for RST or WSM for RSN.
w Inch keyway width tolerances are as follows: over .312” to & including .500” = +.0025”, -.0000”; over .500” to & including 1.000” = +.0030”, -.0000”; 1.000”.
Inch keyway depth tolerance is +.010”, -.000”.
y Maximum for use with packing gland seal.

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 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

with pulleys
WARNING: Consult applicable local and national safety
with belt
WARNING: Lock out power source and remove all external
codes for 1proper guarding
2 of rotating
3 members.
4 5
loads
6 from 7drive before8 servicing drive
9 or accessories.
10 11 12
. . PART NAME RGH. PART NO.
with cover
.
. .
1. ASSEMBLE MOTOR MOUNT AND MOTOR TO DRIVE AS 4. ASSEMBLE SLOT COVER(S) AS REQUIREDX
INSTRUCTED IN APPENDIX D

! WARNING

CH_930001

no screws with screws with cover plate with pulleys

2. A SSEMBLE BELTGUARD BACKPLATE WITH SPACERS TO 5. MOUNT BELT DRIVE AS INSTRUCTED IN APPENDIX D
F
DRIVE FRONT

no screws with screws with cover plate with pulleys with belt
4 5 6 7 8 9 10 11 12 13 14 15 16
no screws with screws with cover plate with pulleys with belt
PART NAME RGH. PART NO. MATERIAL HEAT TREATMENT ROUGH WEIGHT FINISH WEIGHT.
B
X . . . . x lbs [X kgs]
3. ASSEMBLE BELTGUARD BACKPLATE TO MOTOR PLATE 6. MOUNT COVER AND APPLY WARNING LABEL
- TOLERANCE TABLE -
with cover UNLESS OTHERWISE
SPECIFIED
APPLIES TO MACHINED
SURFACES ONLY

1K
PL DEC. = .060
A 2 PL DEC. = .030
3 PL DEC. = .010
ANGLES = 1

1 2 3 4 5 6 7 8 9 10 11 12
! WARNING

CH_930001
J

no screws with screws with cover plate with pulleys

with cover

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E
 Falk® Quadrive® Shaft Mounted Drives Model A • Appendix L
Sizes 5107-5315 (Page 49 of 52)

er and plate
OSHA V-Belt Guard Installation for Drives with Shaft Fan
with sheaves
with belt guard cover

WARNING: Consult applicable local and national safety WARNING: Lock out power source and remove all external
with pulleys with belt
codes for proper guarding of rotating members. loads from drive before servicing drive or accessories.
with cover
1. ASSEMBLE MOTOR MOUNT AND MOTOR TO DRIVE AS 4. INSTALL FAN COVER AND SLOT COVER(S)
INSTRUCTED IN APPENDIX D

with belt guard back with fan with fan cover and plate with sheaves
with belt guard back with hardware with fan cover and plate
with fan
with hardware
2. A
 SSEMBLE BELTGUARD BACKPLATE WITH SPACERS TO 5. MOUNT BELT DRIVE AS INSTRUCTED IN APPENDIX D
DRIVE FRONT AND MOTOR PLATE

! WARNING

CH_930001

! WARNING

CH_930001

with fan with fan cover and plate with sheaves

with hardware
h belt guard back with fan cover and plate
with belt guard cover
with fan with sheaves
with hardware with belt guard cover

3. INSTALL FAN ONTO SHAFT 6. MOUNT COVER AND APPLY WARNING LABEL

! WARNING

CH_930001

with fan with fan cover and plate with sheaves

ith hardware with belt guard cover

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Appendix M • Falk® Quadrive® Shaft Mounted Drives Model A
(Page 50 of 52) Sizes 5307 and 5315

Electric Fan Installation

NOTE: Electric Fan Installation only applies to sizes ASSEMBLY INSTRUCTIONS
5307 and 5315. WARNING: Consult applicable local and national safety
codes for proper guarding of rotating members.
INTRODUCTION Lock out power source and remove all external loads from
The following instructions apply to the installation of electric drive before servicing drive or accessories.
fans. Refer to Figure 1 for fan mounting location. 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
Figure 1 screw away from drive. Secure cap screws to shroud
with flat washers and hex nut. See Figure 2.
MOTOR MOUNT 3. Mount shroud to drive using spacers and hardware.
(SHOWN FOR REFERENCE) See Figure 1.

Figure 2
SPACER SPACER CAP SCREW
.32” LONG 1.45" LONG (4307) SHROUD .25" x 1.25"
0.62" LONG (4315)
CAP SCREW
.625” x 1.25” CAP SCREW HEX NUT
LOCK WASHER .625” x 2.50” (4307) (2) FLAT WASHERS
.625“ x 1.50” (4315)
V-BELT GUARD BRACKET LOCK WASHER LOCKNUT
(SHOWN FOR REFERENCE)
SHROUD
ELECTRIC FAN PANEL

ELECTRIC FAN
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.

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 Falk® Quadrive® Shaft Mounted Drives Model A • Appendix N
Sizes 5215-5315 (Page 51 of 52)

Reliability Package
NOTE: The Reliability Package only applies to sizes LOCATION #2
(ELBOW SUBASSEMBLY)
5215-5315.

INTRODUCTION
The Quadrive Reliability Package shown in Figure 1
includes an enhanced desiccant and particulate filter, anti-
foam block, oil level sight glass and oil sampling port. The
LOCATION #3
(OIL FILL)
AIRMAX PLUS OIL LEVEL
BREATHER SIGHT GLASS LOCATION #1
(SIGHT GLASS
SUBASSEMBLY)

Figure 2 — Pipe Plug Locations

2. Sight Glass Subassembly — Prepare the sight glass
subassembly for installation by applying Loctite joint
compound #1534294 to the male threads as shown in
ANTI-FOAM OIL SAMPLING Figure 3. Install the sight glass subassembly into the
BLOCK PORT Quadrive housing at location #1 as shown in Figure 2.
The galvanized pipe nipple shown in Figure 3 should
Reliability Package will be supplied in two subassemblies,
be used to thread the subassembly hand tight. Using
a prebent hydraulic tube and an AirMax Plus breather that a pipe wrench, turn the pipe nipple an additional 2-3
will need to be assembled by the customer. turns so that it is oil tight. The sight glass should be in
a vertical position when completed as shown in Figure 1.
TABLE 1 — Kit Part Numbers for Quadrive CAUTION: Do not use the sight glass to thread the
Reliability Package assembly into the housing.
Drive Size Kit Part Number
5215J 7708104
5307J 7708105
5315J 7708105 PIPE WRENCH

Figure 1 — Reliability Package

The Quadrive reliability kit part numbers and PIPE NIPPLE
corresponding drive sizes are provided in Table 1.

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 installer’s
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.
Figure 3 — Sight Glass Subassembly

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Appendix N • Falk® Quadrive® Shaft Mounted Drives Model A
(Page 52 of 52) Sizes 5215-5315

3. Elbow Subassembly — Prepare the elbow glycol (PAG) lubricants which are not compatible with
subassembly for installation by applying Loctite joint the polycarbonate sight glass). Once the oil level
compound #1534294 to the male threads as shown reaches the bottom of the fill hole, wait a minimum of 5
in Figure 4. Install the elbow subassembly into the minutes for the oil to reach the oil level sight glass. Add
Quadrive housing at location #2 as shown in Figure 2. additional oil to the gearbox and repeat the process
The galvanized elbow should be used to thread the until the oil level in the gearbox and sight glass are
subassembly hand tight. Using a pipe wrench, turn constant and the excess runs out. It is recommended
the galvanized elbow an additional 2-3 turns so that it to mark the sight glass with this final oil level.
is oil tight. The elbow should be parallel to the output The oil level sight glass is intended to be used when
shaft when finished as shown in Figure 1. the gearbox is not running; in the static condition.
APPLY LOCTITE Therefore, the sight glass contains a label that
JOINT COMPOUND indicates a static oil level. (oil levels tend to fluctuate
#1534294 based on oil churning and are dependent on speed
and direction of rotation; for continuous direction, and
Figure 4 — Elbow subassembly
continuous speed applications it is recommended that
4. AirMax Plus — Prepare the AirMax breather for the oil level sight glass be marked once steady state
installation by removing the two smaller red plastic operating conditions have been reached).
plugs from the bottom air vents located 180°F apart. Prepare the oil fill pipe plug for installation by applying
Also, remove the large red plastic plug from the Loctite joint compound #1534294 to the threads.
breather mounting threads. Thread the breather into Reinstall the elbow subassembly into the Quadrive
the pipe tee of the Reliability Package as shown in housing at location #3 as shown in Figure 2.
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 MAINTENANCE INSTRUCTIONS
AirMax Plus breather (GR3-002). AirMax Breather — Falk AirMax Plus breathers have visual
5. Lifting — The drive can be lifted by using either a indication when they need to be changed. As the breather
sling with a longer housing flange fastener or a sling functions, the silica gel material changes color from blue
wrapped around the seal housing and input shaft. Lift to pink as it absorbs moisture. When all the material has
and mount the drive by following the drive installation turned pink in color, it is time to replace the breather.
and lifting instructions provided in Section 1 (page 7) Breather life is dependent on operating conditions and
of this Owner’s Manual. ambient conditions (humidity). Breather should be changed
every twelve (12) months regardless of color
CAUTION: To prevent damage to the hydraulic tubing, it
should NOT be installed until after the drive has been lifted Oil Sampling — The oil sampling port that is
and mounted into position. Prevent debris from entering the included allows users to easily draw oil samples for
drive by covering the Lenz fittings of the subassemblies, lubrication analysis. Refer to the Oil Analysis Report
until the hydraulic tubing can be installed. section in Appendix A of this document for detailed
recommendations on oil content. The oil sample port has
6. Hydraulic Tubing — Install the hydraulic tubing by
a screw on cover that needs to be unscrewed in order to
following the steps outlined below:
access the valve to the sampling port. The valve can then
1. Remove the nut and tapered split ring from the two be actuated by screwing on the threaded oil sample port
Lenz fittings. adapter included in our Oil Sample Kit (sold separately;
2. Slide the nut and the tapered split ring onto the ends see Table 2). The sampling bottle is composed of PET
of the hydraulic tubing. The large end of the tapered (polyethylene terephthalate) which is compatible with
ring should face the fitting. most industrial lubricants; however, user should confirm
compatibility prior to use. It should be noted that the
3. Apply oil to the O-ring.
cleanliness of the bottle can greatly affect the results of an
4. Insert the ends of the hydraulic tubing simultaneously oil sample analysis; therefore user is cautioned to use care
into the appropriate Lenz fittings.Continue to push the to avoid contamination of the sample.
tubing into the Lenz fittings until the tube ends are
The oil sample should be taken shortly after the unit has
past each o-ring for proper sealing.
been shut down to ensure the oil is properly mixed. It is
NOTE: The hydraulic tubing may have to be bent important to initially purge some oil from the oil sampling
slightly to install it properly into the Lenz fittings thus port and discard this purge, prior to collecting the sample.
ensuring the tubing extends past the o-rings in the Be sure to check the oil level in the drive after the sample
fittings. has been collected (additional oil may need to be added to
5. Once the hydraulic tube is positioned properly, slide ensure proper level).
the tapered spit rings up to the Lenz fittings.
6. Tighten the nut hand tight. Then with a wrench TABLE 2 — Sample Port Adapter, Sampling
tighten one turn or until the rear of the tapered ring is Kit and Breather for use by
flush with the nut. Maintenance Professionals
7. Oil Fill — Remove the oil fill pipe plug from location Part Description Part Number
#3 as shown in Figure 2. Using a funnel with a flexible Oil Sampling Kit (includes oil sample
spout, fill the gearbox with an approved lubricant (refer port adapter, case of 12 sample bottles, 10097025
to Page 23 for Lubrication Recommendations; DO vacuum pump, 20' of tubing and labels)
NOT USE GMAX 6000 or other types of polyalkylene AirMax Plus HG-1 Breather 10097978

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