Dodge 2009 Charger Automobile User Manual

PARTS REPLACEMENT MANUAL
FOR
®
DODGE TORQUE-ARM ™
Speed Reducers
Straight Bore & Taper Bushed
TXT/HXT 309A - 315A - 325A
TXT/HXT 409A - 415A - 425A
TXT/HXT 509B - 515B - 525B
TXT/HXT 609 - 615 - 625
TXT/HXT 709 - 715 - 725
TXT/HXT 305A
TXT/HXT 405A
TXT/HXT 505A
TXT 605
TXT 705
WARNING: Because of the possible danger to persons(s) or property from accidents which may result from the improper use
of products, it is important that correct procedures be followed. Products must be used in accordance with the engineering
information specified in the catalog. Proper installation, maintenance and operation procedures must be observed. The
instructions in the instruction manuals must be followed. Inspections should be made as necessary to assure safe operation
under prevailing conditions. Proper guards and other suitable safety devices or procedures as may be desirable or as may be
specified in safety codes should be provided, and are neither provided by Baldor Electric Company nor are the responsibility of
Baldor Electric Company. This unit and its associated equipment must be installed, adjusted and maintained by qualified
personnel who are familiar with the construction and operation of all equipment in the system and the potential hazards
involved. When risk to persons or property may be involved, a holding device must be an integral part of the driven equipment
beyond the speed reducer output shaft.
INSTALLATION
1.
Use eyebolts or lifting lugs to lift reducer.
For Straight Bore: Mount reducer on driven shaft as close
to bearing as practical. If bushings are used, assemble
bushings in reducer first. A set of bushings for one reducer
consists of one keyseated bushing and one plain bushing.
Extra length setscrews are furnished with the reducer.
Driven shaft should extend through full length of speed
reducer. Tighten both setscrews in each collar.
2. Determine the running positions of the reducer. (See
Fig. 1) Note that the reducer is supplied with either 4 or 7
plugs; 4 around the sides for horizontal installations and 1
on each face for vertical installations. These plugs must be
arranged relative to the running positions as follows:
Horizontal Installations - Install the magnetic drain plug in
the hole closest to the bottom of the reducer. Throw away
the tape that covers the filter/ventilation plug in shipment
and install plug in topmost hole. Of the 3 remaining plugs
on the sides of the reducer, the lowest one is the minimum
oil level plug.
For Taper Bushed: Mount reducer on driven shaft per
instruction sheet No. 499629 packed with tapered
bushings.
Vertical Installations - Install the filter/ventilation plug in the
hole provided in the top face of the reducer housing. Use
the hole in the bottom face for the magnetic drain plug. Of
the 5 remaining holes on the sides of the reducer, use a
plug in the upper housing half for the minimum oil level
plug.
5. Install motor and V-belt drive so belt will
approximately be at right angles to the center line between
driven and input shaft. (See Fig. 3) This will permit
tightening the V-belt with the torque arm.
4. Install sheave on input shaft as close to reducer as
practical. (See Fig. 2)
6. Install torque arm and adapter plates using the long
reducer bolts. The bolts may be shifted to any of the holes
on the input end of the reducer.
7. Install torque arm fulcrum on a flat and rigid support
so that the torque arm will be approximately at right angles
to the center line through the driven shaft and the torque
arm anchor screw. (See Fig. 4) Make sure that there is
sufficient take-up in the turnbuckle for belt tension
adjustment when using V-belt drive.
CAUTION: Unit is shipped without oil. Add proper amount
of recommended lubricant before operating. Failure to
observe this precaution could result in damage to or
destruction of the equipment.
8. Fill gear reducer with recommended lubricant. See
page 3, table 1.
• Below 15 RPM output speed, oil level must be adjusted
to reach the highest oil level plug (P.).
The running position of the reducer in a horizontal
application is not limited to the four positions shown in Fig.
1. However, if running position is over 20* in position "B" &
"D" or 5* in position "A" & "C", either way from sketches,
the oil level plug cannot be used safely to check the oil
level, unless during the checking, the torque arm is
disconnected and the reducer is swung to within 20* for
position "A" & "C" or 5* for position "B" & "D" of the
positions shown in Fig. 1. Because of the many possible
positions of the reducer, it may be necessary or desirable
to make special adaptations using the lubrication filling
holes furnished along with other standard pipe fittings,
stand pipes and oil level gauges as required.
3.
Mount reducer on driven shaft as follows:
WARNING: To ensure that drive is not unexpectedly
started, turn off and lock out or tag power source before
proceeding. Failure to observe these precautions could
result in bodily injury.
2
LUBRICATION
IMPORTANT: Because reducer is shipped without oil, it is
necessary to add the proper amount of oil before running.
Use a high-grade petroleum base rust and oxidation
inhibited (R&O) gear oil - see tables. Follow instructions
on reducer warning tags, and in the installation manual.
CAUTION: Too much oil will cause overheating and too
little will result in gear failure. Check oil level regularly.
Failure to observe this precaution could result in bodily
injury.
Under extreme operating conditions, such as rapid rise
and fall of temperature, dust, dirt, chemical particles,
chemical fumes, or oil sump temperatures above 200°F,
the oil should be changed every 1 to 3 months, depending
on severity of conditions.
Under average industrial operating conditions, the
lubricant should be changed every 2500 hours of
operating or every 6 months, whichever occurs first. Drain
reducer and flush with kerosene, clean magnetic drain
plug and refill to proper level with new lubricant.
CAUTION: Do not use EP oils containing slippery
additives such as graphite or molybdenum disulfide in the
reducer when backstop is used. These additives will
destroy sprag action.
CAUTION: Extreme pressure (EP) lubricants are not
recommended for average operating conditions. Failure to
observe these precautions could result in bodily injury.
Table 1 - Oil Volumes •
Consult DODGE for proper oil level for reducers with backstops and which are mounted in C-position or D-position.
Reducer
Size
TXT/HXT
305A
309A
315A
325A
405A
409A
415A
425A
505A
509B
515B
525B
605
609
615
625
705
709
715
725
† Position A
c
L
Oz.
Qt.
28
.88
.83
Approximate Volume of Oil Required to Fill Reducer to Oil Level Plug
† Position B
† Position C
† Position D
† Position E
c
c
c
c
L
L
Oz.
L
Oz.
L
Oz.
Oz.
Qt.
Qt.
Qt.
Qt.
48
1.50 1.42
44
1.38 1.30
44
1.38 1.30
80
2.50
2.37
Oz.
100
48
1.50
1.42
48
1.50
1.42
24
.75
.71
96
48
1.50
1.42
72
2.25
2.13
68
2.13
2.01
60
1.88
1.77
128
4
3.79
166
4.88
4.62
60
1.88
1.77
72
2.25
2.13
40
1.25
1.18
56
1.75
1.66
108
3.38
3.19
136
4.25
4.02
108
3.38
3.19
136
4.25
4.02
124
3.88
3.67
120
3.75
3.54
248
7.75
7.33
288
9
8.52
104
3.25
3.08
128
4
3.79
104
3.25
3.08
128
4
3.79
224
7
6.62
272
8.50
8.04
144
4.50
4.3
184
5.75
5.4
144
4.50
4.3
160
5
4.7
384
12
11.4
352
11
10.4
72
2.25
2.13
84
2.63
2.48
† Position F
c
L
Qt.
3.13
2.96
3
2.84
136
4.25
4.0
160
5
4.7
136
4.25
4.0
160
5
4.7
276
8.63
8.2
292
9.13
8.6
240
7.50
7.1
288
9
8.5
240
7.50
7.1
296
9.25
8.8
608
19
18
552
17.25
16.3
208
6.50
6.1
256
8
7.6
232
7.25
6.9
296
9.25
8.7
492
15.38
14.6
524
16.38
15.5
† Refer to Figure 1 on page 2 for mounting positions.
c U.S. Measure: 1 quart = 32 fluid ounces = .94646 liters.
Note: If reducer position is to vary from those shown in figure 1,
either more or less oil may be required. Consult Dodge.
If output is less than 15 RPM, consult Dodge.
• Below 15 RPM output speed, oil level must be adjusted to reach the
highest oil level plug (P.).
Table 2 – Oil Recommendations
ISO Grades for Average Operating Conditions
Guidelines for TORQUE-ARM™ Reducer Long-Term
Storage
Ambient Temperatures of 15ºF thru 60ºF
Reducer Size
Output
TXT3A–7
TXT305A–705
RPM
HXT3A–7
HXT305A–505A
301–400
220
201–300
220
151–200
220
126–150
220
101–125
220
81–100
220
41–80
220
11–40
220
1–10
220
During periods of long storage, or when waiting for
delivery or installation of other equipment, special care
should be taken to protect a gear reducer to have it ready
to be in the best condition when placed into service.
By taking special precautions, problems such as seal
leakage and reducer failure due to lack of lubrication,
improper lubrication quantity, or contamination can be
avoided. The following precautions will protect gear
reducers during periods of extended storage:
Ambient Temperatures of 50ºF thru 125ºF
Reducer Size
Output
TXT3A–7
TXT305A–705
RPM
HXT3A–7
HXT305A–505A
301–400
320
201–300
320
151–200
320
126–150
320
101–125
320
81–100
320
41–80
320
11–40
320
1–10
320
Preparation
1. Drain the oil from the unit. Add a vapor phase corrosion
inhibiting oil (VCI-105 oil by Daubert Chemical Co.) in
accordance with Table 3.
2. Seal the unit airtight. Replace the vent plug with a
standard pipe plug and wire the vent to the unit.
3
3. Cover the shaft extension with a waxy rust
preventative compound that will keep oxygen away from
the bare metal. (Non-Rust X-110 By Daubert Chemical
Co.)
4. The instruction manuals and lubrication tags are
paper and must be kept dry. Either remove these
documents and store them inside or cover the unit with a
durable waterproof cover which can keep moisture away.
5. Protect reducer from dust moisture, and other
contaminants by storing the unit in a dry area.
6. In damp environments, the reducer should be packed
inside a moisture-proof container or an envelope of
polyethylene containing a desiccant material. If the
reducer is to be stored outdoors, cover the entire exterior
with a rust preventative.
When placing the reducer into service:
1.
Assemble the vent plug into the proper hole.
2.
Clean the shaft extensions with petroleum solvents.
WARNING: Belt guard removed for illustration
purposes. Do not operate if belt guard is not in place.
3. Fill the unit to the proper oil level using a
recommended lubricant. The VCI oil will not affect the new
lubricant.
REPLACEMENT OF PARTS
4. Follow the installation instructions provided in this
manual
IMPORTANT: Using tools normally found in a
maintenance department, a DODGE TORQUE-ARM
speed reducer can be disassembled and reassembled by
careful attention to the instructions following.
Table 3 – Quantities of VCI #105 Oil
Size
TXT / HXT 3A – 305A
TXT / HXT 4A – 405A
TXT / HXT 5B – 505A
TXT / HXT6 – TXT605
TXT / HXT7 – TXT705
Cleanliness is very important to prevent the introduction of
dirt into the bearings and other parts of the reducer. A tank
of clean solvent, an arbor press, and equipment for
heating bearings and gears (for shrinking these parts on
shafts) should be available.
Quarts or Liters
.1
.2
.3
.4
.5
Our factory is prepared to repair reducers for customers
who do not have proper facilities or who, for any reason,
desire factory service.
VCI #105 & #10 are interchangeable.
VCI #105 is more readily available.
The oil seals are of the rubbing type and considerable
care should be used during disassembly and reassembly
to avoid damage to the surface which the seals rub on.
MOTOR MOUNTS
The keyseat in the input shaft, as well as any sharp edges
on the output hub should be covered with tape or paper
before disassembly or reassembly. Also, be careful to
remove any burrs or nicks on surfaces of the input shaft or
output hub before disassembly or reassembly.
The motor mount must be installed on output end of
reducer as shown in Figure 5.
Remove two or three (as required) housing bolts on output
end of reducer. Place the motor mount in position and
install the longer housing bolts supplied with the motor
mount. Tighten bolts to torque specified in Table 4.
Ordering Parts: When ordering parts for reducer, specify
reducer size number, reducer serial number, part name,
part number, and quantity.
Install motor, drive sheave, and driven sheave so that the
driven sheave is as close to the reducer housing as
practical. Install V-belt and tension with the four adjusting
screws provided on the T-A M motor mount.
It is strongly recommended that, when a pinion or gear is
replaced, the mating pinion or gear is replaced also.
If the large gear on the output hub must be replaced, it is
recommended that an output hub assembly of a gear
assembled on a hub be ordered to secure undamaged
surfaces on the output hub where the output seals rub.
However, if it is desired to use the old output hub, press
the gear and bearing off and examine the rubbing surface
under the oil seal carefully for possible scratching or other
damage resulting from the pressing operation. To prevent
oil leakage at the shaft oil seals, the smooth surface of the
output hub must not be damaged.
Check all bolts to see that they are securely tightened.
4
If any parts must be pressed from a shaft or from the
output hub, this should be done before ordering parts to
make sure that none of the bearings or other parts are
damaged in removal. Do not press against outer race of
any bearing.
5. Place R.H. housing half on blocks to allow for
protruding end of output hub.
Because old shaft oil seals may be damaged in
disassembly, it is advisable to order replacements for
these parts.
7. Mesh output hub gear and small countershaft gear
together and set in place in housing. Set input shaft
assembly in place in the housing. Make sure bearing
rollers (cones) are properly seated in their cups. set
bearing cups for left-hand housing half in place on their
rollers.
6. Install bearing cups in right-hand housing half,
making sure they are properly seated.
Removing Reducer from Shaft
CAUTION: Remove all external loads from drive before
removing or servicing drive or accessories.
8. Clean housing flange surfaces on both halves,
making sure not to nick or scratch flange face. Place a
1/8 bead of RTV732 sealant on flange face. (make sure
RTV is placed between bolt holes and inside of flange
face) Place other housing half into position and tap with a
soft hammer (rawhide, not lead hammer) until housing
bolts can be used to draw housing halves together.
Torque housing bolts per torque values listed in table 4.
WARNING: To ensure that drive is not unexpectedly
started, turn off and lock out or tag power source before
proceeding. Failure to observe these precautions could
result in bodily injury.
Straight Bore: Loosen screws in both output hub collars.
Remove the collar next to the end of the shaft. This
exposes three puller holes in the output hub to permit the
use of a wheel puller. In removing the reducer from the
shaft, be careful not to damage the ends of the hub.
Table 4 – Recommended Torque Values
Reducer
Size
Taper Bushed:
1.
TXT / HXT 305A & 3A
TXT / HXT 405A & 4A
TXT / HXT 505A & 5B
TXT605 & TXT / HXT 6
TXT705 & TXT / HXT 7
Remove bushing screws.
2. Place the screws in the threaded holes provided in
the bushing flanges. Tighten the screws alternately and
evenly until the bushings are free on the shaft. For ease of
tightening screws, make sure screw threads and threaded
holes in bushing flanges are clean.
Reducer
Size
3. Remove the outside bushing, the reducer, and then
the inboard bushing.
TXT / HXT 305A & 3A
TXT / HXT 405A & 4A
TXT / HXT 505A & 5B
TXT605 & TXT / HXT 6
Disassembly:
1. Position the reducer on its side and remove all
housing bolts. Drive dowel pins from housing. Gently tap
the output hub and input shaft with a soft hammer
(rawhide, not a lead hammer) to separate the housing
halves. Open housing evenly to prevent damage to the
parts inside.
TXT705 & TXT / HXT 7
Dry Torque (lb.–ft.)
C’shaft
Input Shaft
Bearing Cover
Seal Carrier
Screws
Screws
17–15
17–15
30–27
30–27
30–27
30–27
30–27
30–27
50–45
50–45
9. Place output hub seal carrier in position without
shims and install two carrier screws diametrically opposed.
Torque each screw to 25 in.-lbs. Rotate the output hub to
roll in the bearings and then torque each screw to 50 in.lbs. Again turn output hub to roll in the bearings. With a
feeler or taper gage, measure the gap between the
housing and the carrier flange. To determine the required
shim thickness, take the average of the two feeler gage
readings. Remove carrier and install the required shims
plus .002. Install carrier with shims and torque bolts per
table 4. Rotate hub assy, tap lightly with rawhide mallet on
end of hub, while rotating, to ensure bearings are seated.
Using a dial indicator check end play of hub bearings,
endplay should be .001-.003. Repeat this process as
necessary to obtain proper end play. Place a 1/8 diameter
bead of RTV732 sealant inside the carrier at the shim I.D.
and install carrier on reducer housing. Torque carrier bolts
to value shown in Table 4.
10. Adjust the countershaft bearings using the same
method as in step 8 above. The axial end play should be
.001” to .003”.
2. Lift shaft, gear, and bearing assemblies from
housing.
3.
Dry Torque (lb.–ft.)
Output Hub
Housing
Seal Carrier
Bolts
Screws
50–45
17–15
50–45
30–27
75–68
30–27
75–68
30–27
150–135
50–45
Remove seals from housing.
Reassembly:
1. Output Hub Assembly: Heat gear to 325°F to 350°F
to shrink onto hub. Heat bearings to 270°F to 290°F to
shrink onto hub. Any injury to the hub surfaces where the
oil seals rub will cause leakage, making it necessary to
use a new hub.
2. Countershaft Assembly: Shaft and pinion are integral.
Press gear and bearings on shaft. Press against inner (not
outer) race of bearings.
3. Input Shaft Assembly: Shaft and pinion are integral.
Press bearings on shaft. Press against inner (not outer)
race of bearings.
11. Again, using the same procedure as in step 8,
adjust the input shaft bearings, except the axial end play
should be .002” to .004”.
4. Drive the two dowel pins into place in the right-hand
housing half. Apply RTV732 sealant to carriers for R.H.
side(backstop side) of reducer. Install carriers and torque
bolts per table 4.
5
11. Using gaskets install input shaft cover and counter
shaft cover to right-hand housing half. Install input and
output seals. Extreme care should be used when installing
seals to avoid damage due to contact with sharp edges on
the input shaft or output hub. The possibility of damage
and consequent oil leakage can be decreased by covering
all sharp edges with tape prior to seal installation. Fill
cavity between seal lips with grease. Seals should be
pressed or tapped with a soft hammer evenly into place in
the carrier, applying pressure only on the outer edge of the
seals. A slight oil leakage at the seals may be evident
during initial running, but should disappear unless seals
have been damaged.
12. Install bushing backup plates and snap rings on
Taper Bushed reducers or hub collars on straight bore
reducers.
Table 5 – Manufacturers’ Part Numbers for Replacement
Output Hub Bearings
Torque–Arm
Reducer
Drive Size
Table 6 cont’d – Manufacturers’ Part Numbers for
Replacement Countershaft Bearings
Torque–Arm
Reducer
Drive Size
TXT/HXT 309A
TXT/HXT 315A
TXT/HXT 325A
TXT/HXT 409A
TXT/HXT 415A
TXT/HXT 425A
TXT/HXT 509A
TXT/HXT 515A
TXT/HXT 525A
TXT/HXT 609
TXT/HXT 615
TXT/HXT 625
TXT/HXT 709
TXT/HXT 715
TXT/HXT 725
Countershaft Bearing
Input Side
Dodge Part No.
Timken Part No.
402273
403094
15102
15245
402000
403000
M86649
M86610
402203
403027
2789
2720
402052
403142
HM803149
HM803110
402256
403053
JHM807045
JHM807012
Table 7 – Manufacturers’ Part Numbers for Replacement
Input Bearings
Output
Bearing
Dodge
Part No.
402272
403127
Timken
Part No.
LM814849
LM814810
TXT/HXT 305A
TXT/HXT 309A
TXT/HXT 315A
TXT/HXT 325A
Input Bearings Input Side
Timken
Dodge
Part No.
Part No.
402190
LM603049
403132
LM603011
402272
403127
LM814849
LM814810
TXT/HXT 309A
TXT/HXT 315A
TXT/HXT 325A
402204
403139
LM48548A
LM48510
TXT/HXT 405A
402268
403163
498
492A
TXT/HXT 405A
402179
403006
368
362A
TXT/HXT 409A
TXT/HXT 415A
TXT/HXT 425A
402268
403163
498
492A
TXT/HXT 409A
TXT/HXT 415A
TXT/HXT 425A
402280
403027
2788
2720
402193
403016
42381
42584
TXT/HXT 505A
TXT/HXT 505A
402270
403026
45289
45220
TXT/HXT 509B
TXT/HXT 515B
TXT/HXT 525B
402193
403016
42381
42584
TXT/HXT 509B
TXT/HXT 515B
TXT/HXT 525B
402144
403104
28579
28521
TXT605
JM822049
JM822010
39580
39520
TXT605
402050
403140
402053
403106
402196
403091
395A
3920
TXT/HXT 609
TXT/HXT 615
TXT/HXT 625
TXT/HXT 609
TXT/HXT 615
TXT/HXT 625
402050
403140
JM822049
JM822010
TXT705
402057
403143
JH211749
JH211710
TXT705
402058
403111
48290
48220
TXT/HXT 709
TXT/HXT 715
TXT/HXT 725
402150
403106
39590
39520
TXT/HXT 709
TXT/HXT 715
TXT/HXT 725
402058
403111
48290
48220
TXT/HXT 305A
Torque–Arm
Reducer
Drive Size
Table 6 – Manufacturers’ Part Numbers for Replacement
Countershaft Bearings
Torque–Arm
Reducer
Drive Size
TXT/HXT 309A
TXT/HXT 315A
TXT/HXT 325A
Countershaft Bearing Input Side
Dodge
Timken
Part No.
Part No.
402273
403094
TXT/HXT 305A
Input Bearings output Side
Dodge
Timken
Part No.
Part No.
402271
02872
403101
02820
TXT/HXT 309A
TXT/HXT 315A
TXT/HXT 325A
402273
403094
15102
15245
TXT/HXT 405A
402285
403125
339
332
TXT/HXT 409A
TXT/HXT 415A
TXT/HXT 425A
402142
403102
26118
26283
TXT/HXT 505A
402266
403073
350A
352
Torque–Arm
Reducer
Drive Size
15102
15245
TXT/HXT 409A
TXT/HXT 415A
TXT/HXT 425A
402000
403000
M86649
M86610
TXT/HXT 509B
TXT/HXT 515B
TXT/HXT 525B
402266
403073
350A
352
TXT/HXT 509A
TXT/HXT 515A
TXT/HXT 525A
402203
403027
2789
2720
TXT605
402123
403009
3975
3926
TXT/HXT 609
TXT/HXT 615
TXT/HXT 625
402054
403159
HM807040
HM807010
TXT/HXT 609
TXT/HXT 615
TXT/HXT 625
402197
403091
396
3920
TXT705
402078
403034
JH307749
JH307710
TXT/HXT 709
TXT/HXT 715
TXT/HXT 725
402256
403053
JHM807045
JHM807012
TXT/HXT 709
TXT/HXT 715
TXT/HXT 725
402088
403047
455
452
6
7
8
9
10
11
12
13
14
15
World Headquarters
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Baldor - Dodge
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com
All Rights Reserved. Printed in USA
07/01/2008
©Baldor Electric Company 2008
499392
16