Parts Replacement Manual

For

DODGE TORQUE-ARM
Speed Reducers
Straight Bore & Taper Bushed

SZES:

TXT109-TXT115-TXT125
TXT 209 - TXT215 - TXT225

WARNING: Because of the possible danger to persons(s) or property from accidentswhich may result from the improper use of products, it is
important that correct procedures be followed. Productsmust be used in accordance with the engineering informationspecified in the catalog.
Proper installation, maintenance and operation procedures must be observed. The instructionsin the instructionmanuals must be followed.
Inspectionsshould be made as necessary to assure safe operation under prevailingconditions.Proper guards and other suitable safety devices
or proceduresas may be desirable or as may be specifiedin safety codes shouldbe provided,and are neither provided by RockwellAutomation
nor are the responsibilityof RockwellAutomation.This unit and its associated equipment must be installed,adjusted and maintained by qualified
personnel who are familiar with the constructionand operation of all equipmentin the systemand the potentialhazards involved.When riskto persons or property may be involved, a holdingdevice must be an integral part of the driven equipmentbeyond the speed reducer output shaft.

DODGE / P.O. Box 499 I6040 Ponders Court I Greenville, SC. 29602-0499 1664-297-4600
0 Rockwell InternationalCorporation, 1997
DODGE and TORQUE-ARM are registered
trademarks of RockwellAutomotion.
Printed in U.S.A.

InstructionManual 499699

Rm

Automation

9/97 lOM-K

INSTALLATION

WARNING
lo ensure that drive is not unexpscteclly started, turn off
and lock out or tag power source before proceeding. Failure
to observe these precautions could result in bodily injury.

1. Use eyebolts to lift reducer.

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 positionsas follows:

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 set-screws in each collar.

Horizontal Installations - Install the magnetic drain plug in the

hole closest to the bottom of the reducer. Throw away the tape
that covers the filler/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.
Vertical Installations - Install the filler/ventilation plug in the
hole provided in the top fbe of the reducer housing. Use the hole
in the bottomface 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.

%AN
KEEP
CLOSE
Fg. 2

For Taper Bushed: Mount

reducer on driven shaft per
instruction sheet No. 499629
packedwith tapered bushings.
4. Install sheave on input shaft
as close to reducer as practical.
(See Fig. 2).

Postion 59

Position 6

HORIZONTAL

I)
L

6. Install torque arm and adaptor plates using the long reducer
bolts.The bolts may be shiftedto
any of the holes on the input end
of the reducer.

0
Positioti F

Lb

0
Position I?
VERTICAL

n
RiGmANGLE
QR MAY VARY
20 EITHER WAY

ToRyNgRM

Fig. 1 -

Position D

Position C
APPLICATIONS

l-l

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.

APPLICATIONS

Mounting Positions

BELT TAKE-UP

Flg.4

The running position of the reducer in a horizontal application

is not limited to the four positions shown in Figure 1. However, if
running position is over 20either way from sketches,the oil level
plug cannot be safely used to check the oil level, unless during the
checking the torque arm is disconnected and the reducer is swung
to within 20 in position B and D or 5 in positionA and C of
the positions shown in Figure .l. Because of the many
possible positionsof the reducer, it may be necessary or desirable
to make special adaptions using the lubrication fitting holes
furnished along with other standard pipe fittings, stand pipes and
oil level gages as required.

7. Install torque arm fulcrum on

a 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.

3. Mount reducer on driven shaft as follows:

8. Fill gear reducer with recommended lubricant.

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.

LUBRICATION
Important: Because reducer is shipped without oil, it is necessary to add the proper amount of oil before running. Use a highgrade petroleum-base, rust and oxidation inhibited (R&O) gear oil
- see tables. Follow instructions on reducer nameplate, 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 2OOF., 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 operation 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 or oils containing slippery

additives such as graphite or molybdenum disulphide 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.
2

Table 1 -

Oil Volumes
Volumeof Oil RequiredmFill
ReducermOil LevelPlug
t PositionA

Reducer
Sii

F,uid
Ounces auartsA
(Appmx) (AppW

TXTlOQ
TX-f115

Fluid
Ounces rh-ts*

fluid
ounces QuarIsA

hid

t PositionE

t Position0

tPosiMnc

t PosiionB

Liters
Liirs
Ounces Puarts
Liirs
Lien
(Approx) (Ap~rox) (Approx) (Approx) (Approx) (Approx) (APPW (Ap~rox) (Approx) (Ag~rox) (Appmx)

16

!4

.47

16

28

56

.B3

32

.47

20

56

.59

24

.95

20

.59

32

tPc&ionF
fluid
Liters ounces auart?

Fluid
Ounces auarts

Liters

(Agprox)
(Ap~roN (Ap~rox)(Ap~rox)

.71

32

.95

52

1%

(ADpmx)

.95

40

1X

1.lQ

1.54

56

1%

1.66

TXl125
TST2OQ
TXl215

I
I
I
I
I
t Referto Fig. 1 on page2 formountingpositions.
TXl225

Note: If reducerpositionis to varyfromthose shownin Figure 1 either

A U.S. Measure: 1 quart = 32 fluidounces= .94646liters.

Table 2-Minimum

more or less oil may be required. Consult faCtOry.

Oil Recommendations for Average Operating Conditions

Lubrication RecommendationeIS0 Grades for Ambient Temperatures of 50 to 125

Lubrication RecommendationaIS0 Grades for Ambient Temperatures of 15 to 60

2O'Fto -22F use Mobil SHCCf7

Abo~el25~F
Use MobilSHC634

Reducer

output

10

12

13

14

15

RPM

150
150
150
150
150
150
150
220
220

150
150
150
150
150
150
150
220
220

150
150
150
150
150
150
150
150
220

150
150
150
150
150
150
150
150
220

150
150
150
150
150
150
150
150
220

150
150
150
150
150
150
150

301-400
201-300
151-200
126-150
101.125
61-100

II I-I
-:zi

ize
6

I 10

I 12

I 13

I 14

41-80
11-40
1.10

MOTOR MOUNTS
The motor mount must be installedon output end of reducer as shown in Figure 5.
Note: the T-A M motor mount is not recommendedfor applications requiring the use of
TRI-MATW overload release.
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 3.

photographicpurposes.

Install motor, drive sheave and driven sheave so that driven sheave is as close to the
reducer housing as practical. Install V-belt and tension with the four adjusting screws
provided on T-A M motor mount.

Warning: Do not operate if bell guard

is not in place.

Check all bolts to see that they are securely tightened.

Fig.5 NOTE: Bell guard removed for

GUIDELINES FOR TORQUE-ARM REDUCER LONG-TERM STORAGE

5. Protect the reducer from dust, moisture, and other contaminants by storingthe unit in a dry area.
6. In damp environments, the reducer should be packed inside a
moisture-proofcontainer 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.

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 the lack of lubrication, improper lubrication quantity, or contamination can be avoided. The following
precautions will protect gear reducers during periods of extended storage:

When placing the reducer into service

1. Assemble the vent plug into the proper hole.

2. Clean the shaft extensionswith petroleumsolvents.

3. Fill the unit to the properoil level using a recommendedlubricant. The VCI oil will not affect the new lubricant.
4. Follow the installationinstructionsprovided in this manual.

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 air tight. Replace the vent plug with a standard
pipe plug and wire the vent to the unit.

Table 3 - Quantities of VCI #105 Oil

DODGE part number 415112-80-DB

3. Cover the shaft extension with a waxy rust preventative compound that will keep oxygen away from the bare metal. (Non-Rust
X-l 10 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.

I
1

Case Size
-.-.
^-.-_
IX11

&lXIZ

I
I

VCI #105 & #lO are interchangeable.

VCI #105 is more readily available.
3

Quarts or Liters

A
1

PARTS FOR TXTl thru TXT2 STRAIGHT BORE & TAPER BUSHED
SPEEDREDUCERS

64
66

Straight Bore

Tooer - Bushed

Note: The two-digit numbers

are for reference only. Order
parts by the six-digit numbers
in the Parts List. Each six-digit
number is a complete identification of the part or assembly.

Toque- Arm Assembly

4

Reference

Name of Pan
BUSHING

70

ASSEMBLY
(Taper
Bushed
DmY)

1 Bore
1XC Bore
1w Bore
1%aBore
11%.Bore
1XC Bore
WBore
1% Bore
1MBore
1WBom
1W Bore
1% Bore
ly Bore

241288
241288
241290
241294
241292
-

72

242148
242150
242152
242154
242158
242158
242182
242184
242188
242188
411390
419010

74

78

1
1
1
1

448271
241308
241807
241306

448281
448281
443281

AKey.

Bushing
to Shaft

1#
Bore
1%; Bore
1%Bore
lU.Bore
13LBore

241310

zz

1T(; Bore
14 Bore
1)LBore
1X, Bore
1WBore
17%.Bore

1
1
1
1
1
1

241305

448282

1'XI'Bore

ZE
242171
242170
-

448284

AKey. Bushingto

OutputHub

1Bore

443272

1X;&

11%.Bore

# thru
AKey,
6

443273

80

TORQUE ARM
ASSEMBLY
ARod End

1
1

241097
241245

243097
243245

:
88

AHex Nut
ATumbuckle
AExtension

1
1

241248
407093
241247

243248
407095
243247

ii

AL.H. Hex Nut

AFulcrum
AFulcrum Screw
AHex Nut

1
1

407242
241249
411458
407091

407244.
243249
411484
407093

ADAPTER ASSEMBLY
ARH. Adapter Ptate
AL.H. Adapter Ptate
AAdapter Bushing
AAdapter Bolt
ALockwasher
AHex Nut

1
1
1
1
1
1
1

259151
241242
241241
242243
411412
419011
407087

259152
242138
242135
243243
411437
419012
407089

92
94
98
98
100
102
104
108
29
84

Alnput Shah Seal

Gasket Eliminator Tuba

1
1

241457

242211

ADutput Hub Seal

241210

242210

39

BEARING KIT
Alnput Shalt Brg (Input)

1
1

389905
424112

389908
424019

:
2

424098
424111
424020

424090
4244X0
424022

2:53
82

~~S*W$ctrsW
AOutput e9

Bushing
to Output Hub

Includespans listedimmediatelybelowmarked A Bushingassembfyincfudes

2 bushings.
AThe parts markeda make up the assembliesunder whichthey are listed.
8 Not shown on drawing.
t 4 reqd. on TXTl; 5 reqd. on TXT2.
t 8reqd.onTXTl;7reqd.onTXT2.
0 StraightBore only.
a Taper Bushed only.
On Size TXT2 for 1r thru 1w bores.

REPLACEMENT OF PARTS
IMPORTANT:

TAPER BUSHED -

Using tools normally found in a maintenance department, a

DODGE TORQUE-ARM speed reducer can be disassembled
and reassembled by careful attention to the instructionsfollowing.

1. Remove bushing screws.

Cleanliness is very important to prevent the introductionof 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, should be available for shrinkingthese parts on shafts.
Our factory is prepared to repair reducers for customers who
do not have proper facilities or who for any reason desire factory
se&e.
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.

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.
3. Remove the outside bushing, the reducer and then the
inboard bushing.
DISASSEMBLY:
1. Position reducer on its side and remove all bolts. 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.

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.

2. Lift shaft, gear, and bearing assemblies from housing.

3. Remove seals from housing.
REASSEMBLY:

ORDERING PARTS:

1. Output Hub Assembly: Heat gear to 325F to 360F to shrink

onto hub. Heat bearings to 270F to 2g6F 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.

When ordering parts for reducer specify reducer size number,

reducer serial number, part name, part number and quantity.
It is strongly recommended that when a pinion or gear is
replaced, the mating gear or pinion be replaced also.

2. Countershaft Assembly: Shaft and pinion are integral. Press

gear and bearings on shaft. Press against inner (not outer) race
of bearings.

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 oil 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 oft leakage at the shaft oil seals the smooth surface of the
output hub must not be damaged.

3. Input Shaft Assembly: Shaft and pinion are integral. Press bearings on shaft. Press against inner (not outer) race of
bearings.
4. Drive the two dowel pins into place in the right-hand housing
half. Position right half of housing (as shown in drawing) on
blocks to allow clearance for protrudingand of output hub.
5. Apply a few drops of oil to all bearings. Mesh output hub
assembly, countershaft assembly and input shaft assembly
together and place in the housing half. Tap lightly with a soft
hammer (nylon or rawhide, not a lead hammer) until bearings
are properly seated. Gearing should spin freely if bearings are
properly seated.

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.
Because old shaft oil seals may be damaged in disassembly it
is advisable to order replacementsfor these parts.

6. Place input housing half into position and tap with a soft hammer until seated and housing flanges are together. Insert and
torque down housing bolts. Spin input shaft to check for any
drag or binding, assemblies will turn freely if housing is properly
seated. Torque housing boftsper torque values listed below.

REMGVING REDUCER FROM SHAFT:

CAUTION: Remove all external loads from drive before
removing or sewicing drive or accessories.

Table 3 -

WARNING
To ensure that drive is not unexpectedly started, turn off and
lock out or tag power source before proceeding. Failure to
observe these precautionscould resuft in bodily injury.

Housing Bolt Torque Values

R%!?r
TxTl &TxT2

STRAIGHT BORE Loosen screws in both output hub collars. Remove the collar
next to end of shaft. This exposes three puller holes in output hub
to permit use of wheel puller. In removihg reducer from shaft be
careful not to damage ends of hub.

Recommended
Torque
360 Ibs.-ins.

Table 5 - Manufacturers Pa t Numbs!rs for

Replacement Countershaft 8 earings

7. Extreme care should be used in installing seals on input

shaft and output hub to avoid damage to seals due to contact
with sharp edges of the keyseat in the input shaft or the retaining ring groove in the output hub. This danger of damage and
consequent oil leakage can be decreased by covering the keyseat and groove with tape or paper which can be removed
subsequently. Chamfer or burr housing bore if end of bore is
sharp or rough. Fill cavity between lips of seal with grease2
Seals should be pressed or tapped with a soft hammer evenly
into place in the housing, applying force only on outer comer of
seals. A slight oil leakage at the seals may be evident during initial running in, but will disappear unless the seals have been
damaged.

Counterstlft Bearing
9
TORQUE-ARM
Adapl!r Side
Reducer
DODGE
SKF
Drive
1 PartNumber
IFWtNumber partNumber PartNumber
Size

KF

g!;i

TxT209
l-XT215
TXT225

424006 1 304SG

424006

424000

424000

305MG*

305MG*

Table 4 - Manufacturers Part Numbers for

Replacement Output Hub Bearings
TORQUE-ARM
Reducer
Drive
Size
TxT109
TxT115
TxTl25
TxT209
TxT215
TXT225

Output Bearing
DODGE
Part Number

SKF
Part Number

424020

6011NR

424022

Table 6 - Manufacturers Part Numbers for

ReDlaCement lnwt Shaft Bearings
InputBearing
InputBearing
O
RQUE-ARM
AdapterSide
Input Side
;educer
SKF
DODGE
DODGE
SKF
lrive
PartNumberPartNumber PartNumber PartNumber
Size

6013NR

TxT109
TxT115
TX-r125
TX-l-209
I-XT215
TXT225

l MRCBRG

424112

205SG
l

424019 I -206MG* I

424011

204MG*

424090

I 305SG

VISCOSITY CLASSIFICATION

EQUIVALENTS

KINEMATIC
VISCOSITIES

SAYBOLT
VISCOSITIES

csu
cst/
40C 100C

sus/
sus/
100F 210F
-10,000
8000
.

2000-

1000-

50-z

80040600500-

300

200

6000
5000

4000

3000

30-

400300-

20-

1000

100

-90

200-800

loo-

lo-

80-

',
8

60-

5040--

30-

s-

20-

4-

600

500

400

300

80

70

-60
-

55

50

45

40

-200

-m-

Viscositiesbased-on66
VI single grade oils.
IS0 are specifiedat
40C.
AGMA are specifiedat
40C.
SAE 75W, 80W and 85W
specifiedat low
temperature.Equivalent
viscositiesfor 100F
and 200F are shown.
SAE 90 to 250 specified
at 100C.

150

100

70

60

50

40

35

32

80