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FALK QUADRIVE JF, Manual

The FALK QUADRIVE JF is a powerful industrial gearbox designed to deliver exceptional performance and reliability. With its comprehensive user manual, available for free download at manualshive.com, you'll have all the guidance needed to maximize the efficiency and productivity of this exceptional product.

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The Falk Corporation, P.O. Box 492, Zip 53201-0492

378-102

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131

August 2004

Fax: 414-937-4359 e-mail: [email protected] web: www.falkcorp.com

Supersedes 6-92

®

a good name in industry

Owners Manual

•

Quadrive Shaft Mounted Drives

(Page 24 of 52)

Sizes 4407/M4407-4608/M4608

This Page Left Intentionally Blank

Summary of Contents for QUADRIVE JF

Page 1: ...QUADRIVE OWNERS PRICE 2 00 PN 2109326 Manual CAUTION Drives are shipped without oil Sizes 4407 M4407 thru 4608 M4608 JR JF JSC a good name in industry ...

Page 2: ...378 102 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 August 2004 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Supersedes 6 92 a good name in industry Owners Manual Quadrive Shaft Mounted Drives Page 2 of 56 Sizes 4407 M4407 4608 M4608 M 4 407 J 25 Size Series Max Bushing Bore 4 7 16 Drive Type Ratio Nominal 25 1 Blank Inch M Metric TA Removal Tool JS...

Page 3: ...Falk If you need repair on Falk products just ask Contact your local Falk Representative or Falk Distributor for more information Table Of Contents Section I Drive Installation Outfitting 4 Installation 6 Lubrication 8 Startup 8 Section II Drive Service Repair Preventive Maintenance 9 Stored Inactive Drives 9 Removal Of Drive 9 Drive Disassembly 11 Identifying Ordering Parts 13 Recommended Spare P...

Page 4: ...aukee WI USA Telephone 414 342 3131 August 2004 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Supersedes 6 92 a good name in industry Owners Manual Quadrive Shaft Mounted Drives Page 4 of 56 Sizes 4407 M4407 4608 M4608 F L 9 O CLOCK F F L L D D D 12 O CLOCK 6 O CLOCK REPOSITION PLUGS TO SUIT REQ D MOUNTING 3 O CLOCK D DRAIN F FILL VENT L OIL LEVEL HIGHEST SIDE PLUG F L D Figur...

Page 5: ...t and insert the thrust plate fastener thru the thrust plate into the drive shaft Tighten fastener to 9500 lb in 1 073 Nm Reinstall hollow shaft cover Continue outfitting based on the type of trough end seal to be installed a Waste Packing Seal or b Lip Seal a WASTE PACKING SEAL Figure 5 Pack seal housing with waste packing and proceed to Step 4 b LIP SEAL Figure 6 Coat outside diameter of seal wi...

Page 6: ... into the hollow shaft keyway DO NOT hammer or use excessive force Refer to Figure 8 for installation of the tie rod The exact position of the tie rod may vary within the range shown For tie rod mountings other than shown refer to Falk If it is necessary to shorten the tie rod cut the excess from either threaded end The support to which the clevis bracket is to be fastened must sustain the torque ...

Page 7: ...tructions 12 JSC 4407 only Assemble drive to trough using fasteners torques given in Table 8 and install drive shaft coupling bolts per screw conveyor manufacturer s instructions Install motor mount motor sheaves belts and guard Refer to Appendix D for instructions 13 JR When the tie rod turnbuckle is used for belt tension adjustment position the motor so that the belt pull will be about 90 to a l...

Page 8: ...e that they have been properly retightened Check correct rotation of motor backstop and be sure drive is properly lubricated After one week of operation repeat check of all external fasteners and pipe plugs 18 After one month of operation a Operate the drive until the sump oil reaches normal operating temperature Shut the drive down and drain immediately b Immediately flush the drive with an oil o...

Page 9: ...l to the proper level with oil meeting specifications given in the Lubrication Recommendation found in Appendix A H Product of the Daubert Chemical Company Chicago Illinois Formerly known as Nucel Oil SHUTDOWN OF NEW OR EXISTING DRIVES WHICH HAVE BEEN OPERATED If a drive is to be stored or inactive for more than 2 months after a period of operation add 1 ounce 0 030 liters of Motorstor H to the oi...

Page 10: ...he threads in the thrust plate If the retaining ring becomes damaged refer to Appendix H for replacement information Proceed as follows JF to Step 5 for replacement of Quadrive seals only OR Step 9 for drive disassembly procedure 4 JSC 4407 only Prepare drive for lifting as shown in Figure 7 Page 6 Remove drive from driven equipment trough end by removing the trough end mounting screws from seal h...

Page 11: ...equipment remove the output shaft cover Ref 14 on Sizes 4407 4507 NO NOT remove seal cages Ref 11 or 12 Sizes 4407 4507 and Ref 22 or 27 Size 4608 Removal of these cages will require readjustment of the bearings Section III Page 21 Refer to Figures 12 13 14 15 and remove seals as follows a Clean shaft extension with solvent and remove all sharp edges Use a sharp center punch to lightly punch the s...

Page 12: ...r reassembly of drive onto driven shaft Drive Disassembly Continued 9 When seals Ref 21 23 4407 4507 Ref 21 37 64 4608 are to be reused Replacement is recommended wrap the input shaft keyway and output shaft threads with masking tape or light weight kraft paper to protect seal lips during disassembly Cover wrapping with a light coat of grease 10 Remove backstop parts if so equipped For Sizes 4407 ...

Page 13: ...and determine the part description and Falk part number using the part reference number Step 1 and the drive identification e g 4407J25 in the column headers of the parts list 3 Use the part description and Falk part number to order the required parts In the examples of preceding Steps 1 and 2 Ref 21 23 100 1A 2A1 and 2A2 for a 4407J25 parts would be ordered as follows Ref 21 Seal cage 4723117 Ref...

Page 14: ...al Quadrive Shaft Mounted Drives Page 14 of 56 Sizes 4407 M4407 4608 M4608 Figure 14 Sizes 4407 thru 4507 34 37 37 35 15 25 22 11 24 4415 4507 ILLUSTRATED 41 42 12 38 10 19 INTERCHANGEABLE 30 29 20 18 28 17 27 4A2 4A5 4A1 4A4 2A2 2A4 2A3 2A1 1A4 1A2 1A1 1A3 1A5 3A2 3A1 3A4 3A3 TYPES J14 J25 TYPE JO5 4A3 4A2 4A5 4A1 4A4 4A6 4A3 4A ASSY 2A ASSY 1A ASSY 10 4A ASSY 3A ASSY 24 11 22 16 34 26 33 31 23 2...

Page 15: ...Shaft Mounted Drives Owners Manual Sizes 4407 M4407 4608 M4608 Page 15 of 56 Figure 15 Size 4608 40 6A1 ASSEMBLY 38 39 11 10 12 31 37 21 30 29 24 22 23 13 TYPE J25 4A ASSEMBLY 2A ASSEMBLY 1A ASSEMBLY 10 17 27 22 INTERCHANGEABLE 23 24 21 39 29 30 31 40 6A1 ASSEMBLY 65 64 39 40 64 40 5A ASSEMBLY 66 39 67 106A 18 63 6A2 6A1 BACK FAN ASSEMBLY FRONT FAN ASSEMBLY 6A1 6A4 6A10 6A3 6A3 6A4 6A11 1A4 1A2 1A...

Page 16: ...Includes Ref 3A4 4723122 4723147 4723168 4A Shaft Assembly Includes Ref 4A1 4A5 4723124 4723150 4723170 4A1 Bearing 2905186 0921861 0921755 4A2 Bearing 2905186 0921861 0921755 4A3 Hollow Shaft Includes Ref 4A5 4723125 4723149 4723171 4A4 Gear 1231140 1231313 1231353 6A1 Fan 4723126 4723126 4723172 6A3 Guard 4721426 4721426 4723173 6A4 Grill 4723127 4723127 4723174 Rotating Elements J14 1A Shaft As...

Page 17: ...sket Kit Includes Ref 12 23 29 39 4723196 106 Tie Rod Anchor Assembly JR only 0712831 Rotating Elements J25 1A Shaft Assembly With 1A4 Gear Without Fan or Backstop 4723197 1A Shaft Assembly With 1A4 Gear With Fan or Backstop 4723198 1A Shaft Assembly Without 1A4 Gear Without Fan or Backstop 4723199 1A Shaft Assembly Without 1A4 Gear With Fan or Backstop 4723200 1A1 Bearing 0921751 1A2 Bearing 0921...

Page 18: ...10 921556 H715332 H715311 921682 HM212049 HM212011 921751 JH217249 JH217210 921752 JH415647 JH415610 921755 JM736149 JM736110 921780 HM212044 HM212011 921855 5584 5535 921857 65212 65500B 921858 65237 65500B 921859 65200 65500B 921860 65225 65500B 921861 67782 67720 921863 5565 5535 2905186 LM330448 LM330410 2905910 LM742749 LM742710 2912058 HM807040 HM807015B 2912059 HM807035 HM807015B H Falk sup...

Page 19: ...sket Ref 11 or 12 and 24 for Sizes 4407 4507 Ref 22 or 27 and 23 for Size 4608 Cross tighten fasteners Ref 34 for Sizes 4407 4507 Ref 24 for Size 4608 to torque specified in Table 14 Check to be sure that cages and covers are registered on the bearing cups to avoid hanging up of the cups b Assemble intermediate end cover and one 015 0 38 mm shim gasket Ref 15 and 25 for Sizes 4407 4507 Ref 29 and ...

Page 20: ...has been removed Use eye bolts to assist in lowering high speed shaft and low speed pinion assemblies Ref 1A 2A and 3A into the housing base Lift the low speed shaft assembly Ref 4A by slinging thru holes in the gear web Assemble as follows a SINGLE REDUCTION Lower high speed shaft assembly Ref 3A Figure 19 into housing and tip away from other housing bores While lowering the low speed shaft assem...

Page 21: ...dicator on the input housing face with the indicator probe on the end of the hollow shaft DO NOT indicate from the thrust plate or fastener head Rotate and oscillate shaft with axial force applied in both directions to obtain the axial float measurement Upward force can be applied by prying upward on the head of the thrust plate bolt If no float is measured remove seal cage and add shim gaskets be...

Page 22: ...31 August 2004 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Supersedes 6 92 a good name in industry Owners Manual Quadrive Shaft Mounted Drives Page 22 of 52 Sizes 4407 M4407 4608 M4608 TABLE 16 Individual Shim Gasket Part Numbers Ref No Shim Thickness Unit Size 4407 4415 4507 4608 100 4723120 0758580 0758587 4723196 12 062 0329946 23 007 1231222 009 0767802 015 0767803 031 0...

Page 23: ...reading the axial float for shaft Ref 1A3 or 3A3 found in Table 15 This indicates the thickness of shim s Ref 31 for Sizes 4407 4507 and Ref 39 for Size 4608 to be removed When removing the shim s retain the 015 0 38 mm thick shim against the housing Ref 10 Retighten fasteners and recheck float Readjust shimming if necessary until proper float is achieved Table 15 7 SEAL INSTALLATION Seals can be ...

Page 24: ...4200 Milwaukee WI USA Telephone 414 342 3131 August 2004 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Supersedes 6 92 a good name in industry Owners Manual Quadrive Shaft Mounted Drives Page 24 of 52 Sizes 4407 M4407 4608 M4608 This Page Left Intentionally Blank ...

Page 25: ...For Vibrations Analysis 43 Appendix J Drive Shaft Recommendations for Tapered Drive Shafts 44 Appendix K Drive Shaft Recommendations Using TA Taper Bushing 45 Appendix L Drive Shaft Recommendations Using TCB Kit 47 Appendix M V Belt Guard Installation 49 Appendix N Electric Fan Installation 51 The Falk Corporation P O Box 492 Zip 53201 0492 378 102 3001 W Canal St Zip 53208 4200 Milwaukee WI USA T...

Page 26: ... 76 East West Extra Duty NL Gear Lube Valvoline Oil Co AGMA EP H Minimum vixcosity index of 90 Maximum operating temperature of lubricants is 200 F 93 C Introduction Lubricants listed in this manual are typical products ONLY and should not be construed as exclusive recommendations Industrial type petroleum based rust and oxidation inhibited R O gear lubricants or industrial type sulfur phosphorus ...

Page 27: ...thetic lube change intervals can be extended to 8000 10 000 hours depending upon operating temperatures and lubricant contamination Laboratory analysis is recommended for optimum lubricant life and drive performance Change lube with change in ambient temperature if required Refer to Table 4 Grease Lubricated Seals All drives are furnished with grease purged seals which minimize the entry of contam...

Page 28: ...Synthetic EP 150 n Spartan Synthetic EP 220 n Spartan Synthetic EP 320 n Mobil Oil Corp SHC 624 SHC 626 SHC 629 SHC 630 SHC 632 Mobilgear SHC 150 n mobilgear SHC 220 n Mobilgear SHC 320 n Pennzoil Products Co Pennzgear SHD 32 Pennzgear SHD 68 Pennzgear SHD 150 Pennzgear SHD 220 Pennzgear SHD 320 Super Maxol S 68 n Super Maxol S 150 n Super Maxol S 220 n Super Maxol S 320 n Petro Canada Products Su...

Page 29: ...ubstitute for a brake Indexing DO NOT use the backstop for indexing applications The backstop is designed to prevent reverse rotation five times or less in eight hours with one minute or more in overrunning direction between backstopping load applications If backstopping operations are more frequent or the time between operations is less than one minute the backstop is classified as an indexing de...

Page 30: ...to lock up the backstop Observe the position of the sprags All Sprags must be engaged and lay in the same relative position around the shaft If the sprags are not uniformly positioned lightly tap the backstop cage to centralize all the sprags around the shaft and cage If sprags cannot be uniformly positioned in this manner remove the backstop and run a finger around the sprags in the overrunning d...

Page 31: ... backstop and normal associated equipment shaft pulleys etc involve moving parts therefore consult local state OSHA and ANSI safety codes for proper guarding of rotating members and possible pinch points If Backstop slippage occurs DO NOT operate Install a new backstop before resuming operation Installation 1 Lock out power source and remove external load from system 2 Clean the backstop bore and ...

Page 32: ...ntamination purge contaminated grease from seal by pumping fresh bearing grease through the bearing cage until it flows out along the shaft Wipe off purged grease Service Removal WARNING DO NOT attempt to service or remove backstop before locking out power source and removing load Backstops must not be dismantled or repaired Backstops are nonserviceable components Replace damaged backstops with a ...

Page 33: ...he drive must be supported during removal process Use a sling around the motor mount or as recommended in SECTION I Step 6 Page 6 Be sure to take up the slack in the sling before proceeding 2 Loosen the setscrew on the O D of the bushing nut Remove the most convenient seal cage nut and lock washer from the stud Figure 2 3 Select the proper adapter from the tool kit Adapters are marked with the Qua...

Page 34: ...re the drive for lifting by disconnecting the tie rod at the drive end 6 ALTERNATE METHOD Torque may be applied to the sheave or sprocket mounted on the input shaft The Falk Corporation P O Box 492 Zip 53201 0492 378 102 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 August 2004 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Supersedes 6 92 a good name i...

Page 35: ...to pads provided on seal cage 2 Assemble rear support bracket to drive a Sizes 4407 thru 4507JR and 4407JF JSC Figure 3 Remove nuts and lock washers from seal cage studs and attach rear support bracket b Sizes 4415 4507 and 4608JF Figure 4 Attach rear support to flange using mounting bolts furnished by user Furnished by Falk for Size 4608JF c Size 4608JR Figure 3 Attach rear support bracket to sea...

Page 36: ...n is reached tighten lock nuts DO NOT over tighten belts Over tightening belts reduces belt and bearing life The Falk Corporation P O Box 492 Zip 53201 0492 378 102 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 August 2004 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Supersedes 6 92 a good name in industry Appendix D Quadrive Shaft Mounted Drives Page...

Page 37: ...il level reaches the Full mark on the dipstick Coat the filler plug not vented with Permatex 3 or equivalent sealant and replace it 10 Filler plug must always be removed to relieve entrapped air before checking oil level High Speed Shaft Up Figure 2 1 After installing the drive per the Owners Manual installation instructions determine which of the lower four side plug locations on the drive will p...

Page 38: ...manent oil level marks on the scribed lines and cut the dipstick to the length marked File end of dipstick smooth 8 Install magnetic drain plug furnished in oil drain location 9 Remove the oil filler plug Add oil until the oil level reaches the Full mark on the dipstick Coat the filler plug not vented with Permatex 3 or equivalent sealant and replace it 10 Filler plug must always be removed to rel...

Page 39: ...waukee WI USA Telephone 414 342 3131 August 2004 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Supersedes 6 92 a good name in industry Quadrive Shaft Mounted Drives Appendix F Sizes 4407 M4407 4608 M4608 Page 39 of 52 10 to 20 Clockwise Rotation 10 to 20 Counterclockwise L L L L L L L L Standard Drive Mounting Limits The 10 Max rotation illustrated at the left applies to stand...

Page 40: ...l Drive Modifications for Inclined H S Shaft L FAR SIDE L L L FAR SIDE FAR SIDE FAR SIDE L L L L Standard Pipe Fittings H Inches 750 14NPT Falk No 1 25 11 5 NPT Falk No 750 Street Elbow 915253 1 25 Street Elbow 915255 750 Cap 914804 1 25 Cap 914806 750 x 1 375 Nipple 915824 1 25 x 1 625 Nipple 915882 750 x 3 Nipple 915836 1 25 x 2 5 Nipple 915885 750 x 500 Bushing 914652 1 25 x 3Nipple 915886 1 25...

Page 41: ...s Ref 24 32 0758573 Rotating Elements J05 3A Shaft Assembly Includes Ref 3A1 3A4 0758567 0758574 0758581 3A3 Pinion Shaft 4723123 4723148 4723169 Rotating Elements J14 1A Shaft Assembly With 1A4 Gear 4723131 1A Shaft Assembly Without 1A4 Gear 0758568 1A2 Bearing 0921872 Rotating Elements J25 1A Shaft Assembly With 1A4 Gear 4723136 4723177 1A Shaft Assembly Without 1A4 Gear 0758569 0758583 1A2 Bear...

Page 42: ...e between Sizes 608J and 4608J All other parts are unique to the specific drive Size 608J or 4608J Refer to Section II Table 11 for Size 4608J parts list Parts Interchangeability Ref No Part Description Drive Size 4608 Housing Components 17 Air Vent 0720000 37 Seal 0912758 38 Seal Cage 4723186 63 Seal Cage 4723187 64 Seal 0912757 65 Shaft Cover 0284960 66 Seal Cage 4723188 67 Yoke 4723194 80 Faste...

Page 43: ... Kits Drive Size Manufacturers Part Number 4407 Truarc N5000 500 4415 Eaton IN 550 4507 Truarc N5000 600 4608 Truarc N5000 725 Type J05 Tooth Combinations Drive Size Exact Ratio Pinion Ref 3A3 Gear Ref 4A4 4407 4 938 16 79 4415 5 077 13 66 4507 4 929 14 69 4608 NA Type J14 Tooth Combinations Drive Size Exact Ratio Input Output Pinion Ref 1A3 Gear Ref 1A4 Pinion Ref 2A3 Gear Ref 4A4 4407 13 78 24 6...

Page 44: ...160 71 1 000 25 40 5 368 136 35 12 020 305 31 7 00 177 8 2 50 63 5 3 10 78 7 1 250 7 2 50 63 5 1 250 0 875 7 75 4608 1 500 38 10 11 500 292 10 7 277 184 84 7 617 193 47 1 000 25 40 6 061 153 95 13 875 352 42 8 50 215 9 3 00 76 2 3 21 81 5 1 250 7 3 00 76 2 1 500 1 500 10 00 H Dimensions are for reference only and are subject to change without notice unless certified Inch keyway width tolerances ar...

Page 45: ...ng ring and spanner nut from the bushing assembly 4407JF Use of the tapered bushing requires that the flange of the bushing be removed to clear the adapter Figure 2 A flangeless bushing is available for the 3 4375 87 mm diameter shaft only ALL JF DRIVES Slide the bushing flange end first onto the drive shaft until it contacts the shoulder on the shaft Insert the key through the bushing and into th...

Page 46: ...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 l The D dimension is the recommended minimum bore which clears the TA Taper bushing flange n Shaft diameter tol...

Page 47: ... as follows The seal housing may be assembled to the drive before or after the drive shaft is installed into the drive but if the seal housing is installed to the drive first the lip type seal if used must be installed from the extension end Slide the bushing large end first onto the drive shaft until it contacts the shoulder on the shaft Insert the key through the bushing and into the drive shaft...

Page 48: ... Kit Part No A 0 010 0 25 B 0 030 0 75 C DA l DB n 0 000 0 003 0 00 0 08 Retaining Ring t Keyway Q S T Min Weld Integral Flange Groove Mfg No Max O D W H L Min F G U V TCB4407J 3 438 0786823 7 655 194 44 9 500 241 30 1 879 47 73 1 552 39 42 3 4375 3 938 100 03 3 263 3 251 0 103 0 108 Spir O Lox RSN 343 0 875 0 4375 9 250 234 95 1 000 8 2 75 69 9 1 500 38 10 Kit consists of Bushing thrust plate fas...

Page 49: ... Appendix M Sizes 4407 M4407 4608 M4608 Page 49 of 52 OSHA V Belt Guard Installation For Drives Without Shaft Fan 1 ASSEMBLE MOTOR MOUNT AND MOTOR TO DRIVE AS INSTRUCTED IN APPENDIX D 4 ASSEMBLE THREADED RODS TO BACKPLATE MOUNT SLOT COVER S AS REQUIRED ALLOW FOR BELT TAKE UP ALLOW FOR BELT INSTALLATION 2 ASSEMBLE BELT GUARD BRACKETS TO MOTOR MOUNT 5 MOUNT BELT DRIVE AS INSTRUCTED IN APPENDIX D 3 A...

Page 50: ...rive Shaft Mounted Drives Page 50 of 52 Sizes 4407 M4407 4608 M4608 OSHA V Belt Guard Installation For Drives With Shaft Fan 1 ASSEMBLE MOTOR MOUNT AND MOTOR TO DRIVE AS INSTRUCTED IN APPENDIX D 4 ASSEMBLE THREADED RODS TO BACKPLATE MOUNT SLOT COVER S AS REQUIRED 2 ASSEMBLE GUARD MOUNTING BRACKET ADAPTER TO GUARD BACKPLATE 5 MOUNT BELT DRIVE AS INSTRUCTED IN APPENDIX D 3 ASSEMBLE BACKPLATE WITH AD...

Page 51: ...f the cap screw away from the drive Secure the cap screws to the shroud with flat washer 2 washers for 4407 and nut see Figure 3 4 Secure the sump temperature switch to the switch mounting bracket Attach the switch and mounting bracket to the fan shroud refer to Figure 2 for location 5 Install the temperature probe bulb well in the designated drain hole as shown in Figure 4 Refer to Figure 2 for b...

Page 52: ...ed from the top of the switch This is the maximum temperature differential setting of 15 F 9 C Replace the cover and four screws 10 Fill drive to oil level specified in Section I with oil specified in Appendix A 11 Position the electric fan panel on the remaining threaded portion of the cap screws from Step 2 and secure it to the shroud with four locknuts see Figure 3 12 Remove the condensation pl...

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