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REPLACEMENT OF PARTS
NOTE: Using tools normally found in a maintenance
department, a Dodge Torque-Arm II speed reducer can be
disassembled and reassembled by careful attention to the
instructions following.
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.
The oil seals are contact lip seals. Considerable care should be
used during disassembly and reassembly to avoid damage to
the surface on which the seals rub.
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.
Ordering Parts: When ordering parts for reducer, specify
reducer size number, reducer model number, part name, part
number, and quantity.
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 consisting of a gear assembled
on a hub be ordered to ensure 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.
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 rollers or cage of any bearing.
Because old shaft oil seals may be damaged in disassembly, it
is advisable to order replacements for these parts.
Removing Reducer from Shaft:
WARNING: To ensure that drive is not unexpectedly
started, turn off and lock out or tag power source before
proceeding. Remove all external loads from drive before
removing or servicing drive or accessories. Failure to
observe these precautions could result in bodily injury.
Taper Bushed:
1.
Disconnect and remove belt guard, v-drive, and motor
mount as required. Disconnect torque arm rod from
reducer adapter.
2.
Remove bushing screws.
3.
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. A tap can be used to
clean out the threads. Use caution to use the proper size
tap to prevent damage to the threads.
4.
Remove the outside bushing, the reducer, and then the
inboard bushing.
Disassembly:
1.
Drain all oil from the reducer.
2.
Position the reducer on its side and remove all housing
bolts. Drive dowel pins from housing. Using the three pry
slots around the periphery of the flange, gently separate the
housing halves. Open housing evenly to prevent damage to
the parts inside.
3.
Lift input shaft, all gear assemblies, and bearing
assemblies from housing.
4.
Remove seals from housing.
5.
Remove bearings from shafts and hubs. Be careful not
to scratch or damage any assembly or seal area during
bearing removal. The hub assembly can be disassembled
for gear replacement but if scratching or grooving occurs
on the hub, seal leakage will occur and the hub will need to
be replaced.
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 race
(not cage or rollers) of bearings.
3.
Input Shaft Assembly: Shaft and pinion are integral. Press
bearings on shaft. Press against inner race (not cage or
rollers) of bearings.
4.
Drive the two dowel pins into place in the right-hand
housing half.
5.
Place R.H. housing half on blocks to allow for protruding
end of output hub.
6.
Install bearing cups in right-hand housing half, making
sure they are properly seated. The output hub assembly
has one bearing pressed against the gear and the other
bearing pressed against a shoulder on the hub. For double
reduction reducers, install the output hub assembly so that
the end where the bearing is pressed against the gear is
up. For single reduction reducers, install the output hub
assembly so that the end where the bearing is pressed
against the gear is down.
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.
8.
Making sure both housing halves are clean, set left-hand
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. Make sure reducer shafts
do not bind while tightening housing bolts.
9.
Rotate the input shaft and seat all bearings with a soft
hammer. Using a magnetic base and indicator, measure
and record the end play of the input shaft, countershaft,
and output hub. Remove left housing half and shim behind
the bearing cup as required to achieve the correct bearing
end play or preload per Table 8. Repeat this process and
check end play until proper end play is obtained. Note that
the output shaft is preloaded. After end play is determined,
add the correct shim thickness to the end play reading to
obtain the correct preload.
17
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