Installation and Maintenance of Shrink Discs • Falk® Gear Drives

All Types & Sizes (Page 1 of 6)

How to Use This Manual 4. With shrink disc in its proper position on the gear drive
hollow shaft, use a torque wrench and tighten all locking
This manual provides detailed instructions on installation screws ¼ turn at a time, progressing around the flange
and maintenance of shrink discs on Falk parallel shaft in either direction until the specified torque is achieved
Type ARJ - Sizes 405-555, Types DHJ & DVJ - Sizes on all locking screws.
M1130-M1210, Type VPJ - Sizes M107-M227 and right
angle shaft Types ABRJ & ABRCJ - Sizes 405-555, Types 5. Check that the shrink disc outer collars are still parallel
DBT & DXJ - Sizes M1130-M1210 and Type VRJ - Sizes within the permissible gap variation (i.e. gap tolerance)
M107-M227. as listed in Table 1. To do so, measure the gap between
outer collars in 4 location at 90 degree intervals.
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS Subtract the minimum gap value measured from the
MANUAL FOR OPTIMUM PERFORMANCE AND maximum gap value measured. This is your gap
TROUBLE FREE SERVICE OF YOUR FALK GEAR DRIVE. variation. If it exceeds the variation listed in Table 1,
the collars are not parallel. You will need to re-install
Installation Instructions to ensure the shrink disk will hold proper torque. Once
parallelism is confirmed, check to make sure that
New shrink discs are supplied ready for installation. If no screw will turn any more by applying specified
spacers were used to protect the shrink disc during tightening torque listed in Table 2.
shipment, remove them now before proceeding. Figure 1
shows a cutaway drawing of a typical shrink disc.
Removal
Remove the drive from the shaft using the following
Non-Contact IMPORTANT!
Area procedure:
Carefully Clean Driven Outer Collars
Shaft & Hollow Shaft Bore 1. Loosen locking screws ½ turn at a time progressing
& Keep Free of Any around the flange in either direction until the shrink disc
Lubricant
is loose on the hollow shaft. Do not completely remove
the locking screws.
On vertical drives, support driven shaft before loosening
Driven the shrink disc fasteners and removing keeper plate/
Shaft Inner Ring driven shaft fastener. The keeper plate has a tapped hole
Hollow Shaft for a larger fastener to assist in shaft removal if needed.
2. Suspend gear drive assembly. Disconnect tie rod or
drive mounting and slide gear drive off of driven shaft.
Metric Hex Head Locking Screws Clean hollow shaft OD outside of shrink disc and slide
DIN 931, Class 10.9 shrink disc off of hollow shaft.
FIGURE 1 - TYPICAL SHRINK DISC
Reinstallation
In clean operating conditions, shrink discs can be reused
IMPORTANT: Never tighten the shrink disc locking screws
without cleaning and relubricating the inner ring, outer ring
unless the driven shaft is inserted into the gear drive hollow
tapers and locking screws.
shaft with full engagement under the shrink disc. Without
the driven shaft in place, plastic deformation of the hollow Shrink discs that require cleaning should be thoroughly
shaft and shrink disc inner ring can occur. Install using the cleaned. The tapers of the inner ring, tapers of the outer
following procedure: collars and the locking screw threads and head washer
faces should be lubricated with molybdenum disulfide
1. Clean hollow shaft OD and shrink disc inner ring bore. grease before reinstallation.
Lightly lubricate hollow shaft OD with light mineral oil.
Slide shrink disc onto shaft to its proper position (Figure Damaged O-rings should be replaced.
2, Page 2). Be certain that inner edge of shrink disc
inner ring is not hung up on a shaft radius. Hand tighten Table 1 — Permissible Outer Collar Gap
three or four locking screws equally spaced around Variation
flange while maintaining outer collars parallel. This will Maximum Collar Gap Variation (Gap Tolerance)
properly seat the outer collars on the taper of the inner SHRINK DISC SIZE
ring and avoid cocking of the collars. Hand tighten Inch mm
remaining fasteners. 24-100 .015 .38
100-260 .032 .81
2. Carefully clean hollow shaft bore under shrink disc and 280-500 .062 1.57
driven shaft OD of all lubricants with solvent before
assembly of gear drive to driven shaft (Figure 1). Any
traces of lubricant left on the driven shaft or hollow shaft Table 2 — Shrink Disc Locking Screw
bore under the shrink disc will significantly reduce the Tightening Torques, –0%+5%
torque transmission capacity of the shrink disc. Screw Size M5 M6 M8 M10 M12 M16 M20 M24 M27
3. Suspend and slide the gear drive into its proper position Head Size (mm) 8 10 13 17 19 24 30 36 41
on the driven shaft (Figure 3, Page 2). Install keeper
Torque
plate assembly (when used) and tighten fasteners to
the torque specified in Table 3 (Inch) or Table 4 (Metric). Lb-Ft 3.6 8.7 22 44 74 185 361 620 922
Nm 5 12 30 59 100 250 490 840 1250

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-850

Telephone: 513-455-5030 Fax: 414-937-4359 February 2019
www.rexnord.com Supersedes 09-12
Installation and Maintenance of Shrink Discs • Falk® Gear Drives
(Page 2 of 6) All Types & Sizes

Table 3 — ARJ & ABRJ – Keeper Plate Table 4 — VPJ, VRJ, DHJ, DBJ DVJ & DXJ –
Fastener Tightening Torque- Inch Keeper Plate Fastener Tightening
Fastener Torque - Metric
Keeper Plate/Hollow Shaft Keeper Plate/Driven Shaft
Location Fastener
Location Keeper Plate/Hollow Shaft Keeper Plate/Driven Shaft
Fastener
Size (UNC) .375 .500 .625 1.25 1.50 2.00 Q Fastener Size
Grade 5 Min (Class 8.8 M6 x M8 x M10 x M12 x M16 x M20 x M24 x M30 x M36 x M48 x
Min) 1.00 1.25 1.50 1.75 2.00 2.50 3.00 3.50 4.00 5.00
Torque (lb-ft) 28 69 137 1050 1840 5850
44 ASTM A354 Gr. BC. Fastener Torque
Lb-ft 8 18 36 62 158 305 530 1060 1860 4550
Nm 10 24 50 84 214 415 705 1440 2520 6150

- INCORRECT -
HUNG UP ON
SHAFT RADIUS

HOLLOW SHAFT HOLLOW SHAFT HOLLOW SHAFT

DRIVEN SHAFT DRIVEN SHAFT DRIVEN SHAFT

- INCORRECT -
CORRECT SHRINK DISC - INCORRECT -
OVERHANGING COCKED
SHAFT END

FIGURE 2 - SHRINK DISC LOCATION

HOLLOW SHAFT HOLLOW SHAFT

DRIVEN SHAFT DRIVEN SHAFT

- INCORRECT-
CORRECT DRIVEN SHAFT
LOCATION

FIGURE 3 - DRIVEN SHAFT LOCATION

168-850 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

February 2019 Telephone: 513-455-5030 Fax: 414-937-4359
Supersedes 09-12 www.rexnord.com
 Installation and Maintenance of Shrink Discs • Falk® Gear Drives
All Types & Sizes (Page 3 of 6)

Type ARJ & ABRJ

Hollow Low Speed Shaft — Shrink Disc Mounted
The drive package includes the keeper plate and keeper plate retention hardware

L3
AJ U INSTALLATION
D A threaded rod is inserted through
L2 L1 the keeper plate center hole and into
the tapped hole in the end of the driven
shaft. The threaded rod, with nut as
shown, are used to aid assembly.

Installation and removal can be

Z - QUANTITY assisted through the use of
ZA - DIA. UNC TAPPED HOLES IN HOLLOW SHAFT additional hardware items
ZB - DEEP shown shaded (customer-supplied)
Y - DIA. BOLT CIRCLE - EQUALLY SPACED HOLES
FOR KEEPER PLATE RETENTION

ASSEMBLED
Hollow Low Speed Shaft Dimensions — Inches
DRIVE AJ † U
SIZE +.0016 D L1 L2 L3 +.002 Z ZA ZB Y
 –.0000 –.000
405 5.2505 5.400 2.50 3.50 24.70 5.500 8 .375-16 .75 6.00
425 6.0005 6.100 3.50 5.00 29.10 6.250 8 .375-16 .75 6.75
445 6.5005 6.600 3.50 6.00 31.80 6.750 6 .500-13 1.00 7.50
465 7.2505 7.400 3.50 6.50 34.10 7.500 6 .500-13 1.00 8.25
485 8.5005 8.625 5.00 8.00 37.30 8.750 6 .500-13 1.00 9.75 REMOVAL
505 9.7505 9.880 4.00 8.20 43.37 10.000 6 .625-11 1.25 11.25 A fastener (larger dia than the
535 10.5005 10.600 4.00 9.37 43.24 10.750 8 .625-11 1.25 12.00 threaded rod) is threaded into the tapped
center hole of the keeper plate and is used to
555 11.4005 11.450 4.50 9.40 50.27 11.750 12 .625-11 1.25 12.90 separate the driven shaft from the hollow
++ Dimensions are for reference only and are subject to change without notice unless certified. low-speed shaft of the gear drive.
†† AJ tolerance for Size 485 is +.0020, –.0000.

GAP (WHEN ASSEMBLED)

R
S - TAP
T - DEEP LC
P
IN END OF LB LA
DRIVEN SHAFT

DC
DB DD DA
DP

Fastener and flat washer

supplied by customer RADIUS RADIUS RADIUS

Driven Shaft Recommended Dimensions — Inches

DRIVE DA DB DD Fastener Tapped Hole
DC Radius
SIZE +.0000 +.000 +.010 LA LB LC DP P R S T in Center of Gap
 Min Max Length Keeper
–.0015 –.001 –.010 Plate
405 5.500 5.250 6.00 5.312 .125 2.38 3.75 24.58 6.88 .75 1.76 1.250-7 2.50 2.50 1.750-5 0.12
425 6.250 6.000 6.75 6.062 .125 3.38 5.25 28.98 7.62 .75 1.76 1.250-7 2.50 2.50 1.750-5 0.12
445 6.750 6.500 7.25 6.531 .125 3.38 6.25 31.68 8.62 1.00 2.18 1.500-6 3.00 3.00 2.000-4.5 0.12
465 7.500 7.250 8.25 7.312 .125 3.38 6.75 33.98 9.38 1.00 2.18 1.500-6 3.00 3.00 2.000-4.5 0.12
485 8.750 8.500 9.50 8.562 .125 4.88 8.25 37.18 10.88 1.00 2.18 1.500-6 3.00 3.00 2.000-4.5 0.12
505 10.000 9.750 10.75 9.800 .125 3.88 8.40 43.20 12.75 1.25 2.42 1.500-6 3.00 3.25 2.000-4.5 0.17
535 10.750 10.500 11.50 10.520 .125 3.88 9.60 43.00 13.50 1.25 2.75 2.000-4.5 4.00 4.00 2.500-4 0.24
555 11.750 11.400 12.50 11.370 .125 4.38 9.60 50.00 14.30 1.50 3.00 2.000-4.5 4.00 4.00 2.500-4 0.27
++ Dimensions are for reference only and are subject to change without notice unless certified.

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-850

Telephone: 513-455-5030 Fax: 414-937-4359 February 2019
www.rexnord.com Supersedes 09-12
Installation and Maintenance of Shrink Discs • Falk® Gear Drives
(Page 4 of 6) All Types & Sizes

Type DHJ, DBJ, DVJ & DXJ

Hollow Low Speed Shaft - Shrink Disc Mounted/Dimensions — Inches
The drive package includes the keeper plate and keeper plate retention hardware

.015 R MAX

L3
U
AJ
D INSTALLATION
L2 L1 A threaded rod is inserted through
the keeper plate center hole and into
the tapped hole in the end of the driven
shaft. The threaded rod, with nut as
shown, are used to aid assembly.

Z - QUANTITY
ZA - DIA. TAPPED HOLES IN HOLLOW SHAFT
ZB - DEEP Installation and removal can be
Y - DIA. BO LT CIRCLE - EQUALLY SPACED HOLES assisted through the use of
FOR KEEPER PLATE RETENTION additional hardware items
shown shaded (customer-supplied)

Hollow Low Speed Shaft Dimensions — Inches

ASSEMBLED
DRIVE AJ † D L1 L2 L3 U‡ Z ZA ZB Y
SIZE 
M1130 3.3465 3.465 2.362 2.362 15.512 3.543 8 M6 x 1-6H 0.472 3.780
M1140 3.9370 4.055 2.559 2.559 17.677 4.134 8 M6 x 1-6H 0.472 4.331
M1150 4.3307 4.449 2.756 2.756 19.191 4.528 8 M8 x 1.25-6H 0.630 4.803
M1160 5.1181 5.236 3.543 3.543 20.628 5.315 8 M10 x 1.50-6H 0.787 5.787
M1170 5.5118 5.630 3.543 3.543 21.181 5.709 8 M10 x 1.50-6H 0.787 6.181
M1180 6.4961 6.614 4.331 4.331 24.724 6.693 6 M12 x 1.75-6H 1.102 7.520
M1190 7.0866 7.205 4.724 4.724 26.694 7.283 6 M12 x 1.75-6H 1.102 8.268 REMOVAL
M1200 7.8740 8.071 5.118 5.709 29.921 8.268 6 M12 x 1.75-6H 0.945 9.055 A fastener (larger dia than the
M1210 7.8740 8.071 5.008 5.709 29.921 8.268 6 M12 x 1.75-6H 0.945 9.055 threaded rod) is threaded into the tapped
center hole of the keeper plate and is used to
++ Dimensions are for reference only and are subject to change without notice unless certified. separate the driven shaft from the hollow
†† J7 tolerance. low-speed shaft of the gear drive.
‡‡ H7 tolerance.
GAP (WHEN ASSEMBLED)
R
S - TAP
T - DEEP LC
P
IN END OF LB LA
DRIVEN SHAFT

DC
DB DD DA
DP

Fastener and flat washer

supplied by customer RADIUS RADIUS RADIUS

Driven Shaft Recommended Dimensions — Inches

Fastener Tapped Hole
DRIVE DC Radius
DA † DB ‡ DD  LA LB LC DP P R S T in Center of Gap
SIZE  Min Max Length Keeper Plate
M1130 3.5433 3.3465 4.134 3.465 0.118 2.126 2.598 15.354 4.33 0.591 1.22 M20 x 2.5-6H 1.654 2.36 M24 x 3-6H 0.157
M1140 4.1339 3.9370 4.724 4.055 0.118 2.323 2.795 17.520 4.84 0.591 1.34 M24 x 3-6H 1.969 2.76 M30 x 3.5-6H 0.157
M1150 4.5276 4.3307 5.118 4.449 0.118 2.520 2.992 19.016 5.47 0.787 1.54 M24 x 3-6H 1.969 2.95 M30 x 3.5-6H 0.157
M1160 5.3150 5.1181 5.906 5.236 0.118 3.307 3.780 20.472 6.46 0.787 1.54 M24 x 3-6H 1.969 2.95 M36 x 4-6H 0.157
M1170 5.7087 5.5118 6.299 5.630 0.118 3.307 3.780 21.024 6.85 0.787 1.69 M30 x 3.5-6H 2.362 3.15 M42 x 4.5-6H 0.157
M1180 6.6929 6.4961 7.283 6.614 0.118 4.094 4.567 24.567 8.62 0.787 1.89 M36 x 4-6H 2.913 3.54 M48 x 5-6H 0.157
M1190 7.2835 7.0866 7.874 7.205 0.118 4.488 4.961 26.535 9.25 0.748 1.85 M36 x 4-6H 2.913 3.54 M48 x 5-6H 0.157
M1200 8.2677 7.8740 9.055 8.071 0.118 4.882 5.472 29.764 10.16 0.984 2.09 M36 x 4-6H 2.913 3.94 M48 x 5-6H 0.157
M1210 8.2677 7.8740 9.055 8.071 0.118 4.882 5.472 29.764 10.16 0.984 2.09 M36 x 4-6H 2.913 3.94 M48 x 5-6H 0.157
++ Dimensions are for reference only and are subject to change without notice unless certified.
†† h6 tolerance.
‡‡ g6 tolerance.
zz c11 tolerance.

168-850 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

February 2019 Telephone: 513-455-5030 Fax: 414-937-4359
Supersedes 09-12 www.rexnord.com
 Installation and Maintenance of Shrink Discs • Falk® Gear Drives
All Types & Sizes (Page 5 of 6)

Type VPJ & VRJ Sizes 107-187

Hollow Low-Speed Shaft — Shrink Disc Mounted/Dimensions — Inches
The drive package includes the keeper plate and keeper plate retention hardware
.015 R MAX

L3
U
AJ
D
L2 L1 INSTALLATION
A threaded rod is inserted through
the keeper plate center hole and into
the tapped hole in the end of the driven
shaft. The threaded rod, with nut as
shown, are used to aid assembly.
Z - QUANTITY
ZA - DIA. TAPPED HOLES IN HOLLOW SHAFT
ZB - DEEP
Y - DIA. BO LT CIRCLE - EQUALLY SPACED HOLES
FOR KEEPER PLATE RETENTION Installation and removal can be
assisted through the use of
additional hardware items
shown shaded (customer-supplied)

Hollow Low-Speed Shaft Dimensions — Inches ASSEMBLED

DRIVE SIZE AJ D L1 L2 L3 U Z ZA ZB Y
107 3.3465 J7 3.465 2.36 2.36 15.67 3.5433 H7 8 M6 x 1.00 0.47 3.780
117 4.1339 J7 4.252 2.95 2.36 18.19 4.3307 H7 8 M8 x 1.25 0.63 4.803
127 4.9213 J7 5.039 2.76 2.76 19.53 5.1181 H7 8 M8 x 1.25 0.63 5.512
133, 137 5.3150 J7 5.433 3.54 3.54 20.63 5.5118 H7 8 M8 x 1.25 0.63 5.827
143, 145, 147 5.9055 J7 6.024 3.74 3.74 22.17 6.1031 H7 8 M8 x 1.25 0.63 6.575 REMOVAL
A fastener (larger dia than the
153, 155, 157 6.4961 J7 6.614 4.33 4.13 24.96 6.6937 H7 6 M12 x 1.75 1.10 7.520 threaded rod) is threaded into the tapped
163, 165, 167 7.0866 J7 center hole of the keeper plate and is used to
7.205 4.72 4.13 27.01 7.2835 H7 6 M12 x 1.75 1.10 8.268 separate the driven shaft from the hollow
173, 175, 177 7.8740 J7 8.071 5.12 4.72 29.92 8.2677 H7 6 M12 x 1.75 0.945 9.055 low-speed shaft of the gear drive.

187 8.0709 J7 8.189 5.12 4.72 29.92 8.2677 H7 6 M12 x 1.75 0.945 9.055

GAP (WHEN ASSEMBLED)

R
S - TAP
T - DEEP LC
P
IN END OF LB LA
DRIVEN SHAFT

DC
DB DD DA
DP

Fastener and flat washer

supplied by customer RADIUS RADIUS RADIUS

Driven Shaft Recommended Dimensions — Inches

Fastener Tapped Hole
DRIVE DC Radius
DA DB DD LA LB LC DP P R S T in Center Gap
SIZE Min Max Length of Keeper Plate
107 3.5433 h6 3.3465 g6 4.13 3.4646 c11 0.118 2.13 2.598 15.512 4.33 0.59 1.22 M20 x 2.5 1.57 2.17 M24 x 3.0 0.16
117 4.3307 h6 4.1339 g6 4.92 4.2520 c11 0.118 2.72 2.598 18.031 5.47 0.63 1.38 M24 x 3.0 1.89 2.56 M30 x 3.5 0.16
127 5.1181 h6 4.9213 g6 5.71 5.0394 c11 0.118 2.520 2.992 19.370 6.06 0.75 1.54 M24 x 3.0 1.89 2.76 M30 x 3.5 0.16
133, 137 5.5118 h6 5.3150g6 6.10 5.4331 c11 0.118 3.307 3.780 20.472 6.46 0.75 1.54 M24 x 3.0 1.89 2.76 M36 x 4.0 0.16
143, 145, 147 6.1024 h6 5.9055g6 6.69 6.0236 c11 0.118 3.504 3.976 22.008 6.85 0.75 1.69 M30 x 3.5 2.36 3.15 M42 x 4.5 0.16
153, 155, 157 6.6929 h6 6.4950g6 7.28 6.6142 c11 0.118 4.094 4.370 24.803 8.62 0.75 1.89 M36 x 4.0 2.91 3.54 M48 x 5.0 0.16
163, 165, 167 7.2835 h6 7.0866g6 7.87 7.2047 c11 0.118 4.488 4.370 26.850 9.25 0.75 1.85 M36 x 4.0 2.913 3.54 M48 x 5.0 0.16
173, 175, 177 8.2677 h6 7.8740g6 9.06 8.0709 c11 0.118 4.882 4.961 29.764 10.16 1.00 2.09 M36 x 4.0 2.913 3.94 M48 x 5.0 0.16
187 8.2677 h6 8.0709g6 9.06 8.1890 c11 0.118 4.882 4.961 29.764 10.16 1.00 2.09 M36 x 4.0 2.913 3.94 M48 x 5.0 0.16

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-850

Telephone: 513-455-5030 Fax: 414-937-4359 February 2019
www.rexnord.com Supersedes 09-12
Installation and Maintenance of Shrink Discs • Falk® Gear Drives
(Page 6 of 6) All Types & Sizes

Type VPJ & VRJ Sizes 203-227

Hollow Low-Speed Shaft — Shrink Disc Mounted/Dimensions — Inches
The drive package includes the keeper plate and keeper plate retention hardware

.015 R MAX

L3
U
AJ INSTALLATION
D A threaded rod is inserted through
L2 L1 the keeper plate center hole and into
the tapped hole in the end of the driven
shaft. The threaded rod, with nut as
shown, are used to aid assembly.

Installation and removal can be

Z - QUANTITY assisted through the use of
ZA - DIA. TAPPED HOLES IN HOLLOW SHAFT
ZB - DEEP additional hardware items
Y - DIA. BO LT CIRCLE - EQUALLY SPACED HOLES shown shaded (customer-supplied)
FOR KEEPER PLATE RETENTION

ASSEMBLED
Hollow Low-Speed Shaft Dimensions — Inches
DRIVE AJ D L1 L2 L3 U Z ZA ZB Y
SIZE
203
207 10.2362J7 10.433 7.874 7.480 42.520 10.6299H7 10 M12 x 1.75-6H 0.95 11.417
223
225 12.2047J7 12.402 8.071 8.071 47.441 12.5984H7 10 M16 x 2.0-6H 1.26 13.583
227
REMOVAL
A fastener (larger dia than the
threaded rod) is threaded into the tapped
center hole of the keeper plate and is used to
separate the driven shaft from the hollow
low-speed shaft of the gear drive.

GAP (WHEN ASSEMBLED)

R
S - TAP
T - DEEP LC
P
IN END OF LB LA
DRIVEN SHAFT

DC
DB DD DA
DP

Fastener and flat washer

supplied by customer RADIUS RADIUS RADIUS

Driven Shaft Recommended Dimensions — Inches

Fastener Tapped Hole
DRIVE DC Radius
DA DB DD LA LB LC DP P R S T in Center Gap
SIZE Min Max Length of Keeper Plate
203
207 10.6299 h6 10.2362 g6 11.614 10.4331 c11 0.157 7.638 7.559 42.362 12.52 1.260 2.76 M48 x 5-6H 3.780 4.72 M64 x 6-6H 0.157
223
225 12.5984 h6 12.2047 g6 13.583 12.4016 c11 0.157 7.835 8.150 47.283 14.88 1.260 2.76 M48 x 5-6H 3.780 4.72 M64 x 6-6H 0.157
227

168-850 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

February 2019 Telephone: 513-455-5030 Fax: 414-937-4359
Supersedes 09-12 www.rexnord.com