1WARNING: 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. WARNING:Onlyqualiedpersonnelfamiliarwiththe constructionandoperationofthisequipmentandthe hazardsinvolvedshouldinstall,adjust,operate,and/or servicethisequipment.Readandunderstandthismanual initsentiretybeforeproceeding.Failuretoobservethis precaution could result in bodily injury.GENERAL INFORMATIONTheDODGEMAXUMreducerandscoopmotor/reducerare designedinaccordancewiththestandardsoftheAmerican GearManufacturersAssociationtogiveyearsoftrouble-free operation.Inordertoobtaingoodperformance,thereare precautionsandproceduresthatshouldbeobservedwhen installing and servicing the unit. This instruction manual contains installation,operatingandmaintenanceinformationforyour reduceranditsaccessories.Additionalinformationcanbe obtainedbycontactingyourlocalBaldorElectricsalesoffce, distributor or authorized service center.Warranty & OperationThisequipmentiswarrantedunderBaldorElectricCompany Standard Conditions of Sale. Adequateinstructionsmustbegivenbytheusertopersonnel responsible for the operation of the equipment. Theuserisalsoresponsibleforinstallationofguardsand equipment needed to protect the operating personnel.Design FeaturesThefollowinginformationappliestothestandardDODGE MAXUMreducers.Yourdesignmayvaryfromstandard arrangements covered by these instructions. When this occurs, contact Dodge Product Support. WARNING: Because of the possible danger to person(s) or property from accidents which may result from the improper use of products, it is important that correct procedures be followed.Productsmustbeusedinaccordancewiththe engineeringinformationspeciedinthecatalog.Proper installation,maintenanceandoperationproceduresmust beobserved.Theinstructionsintheinstructionmanuals 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 maybedesirable,orasmaybespeciedinsafetycodes shouldbeprovided,andareneitherprovidedbyBaldor ElectricCompany,noraretheresponsibilityofBaldor ElectricCompany.Thisunitanditsassociatedequipment mustbeinstalled,adjustedandmaintainedbyqualied personnelwhoarefamiliarwiththeconstructionand operationofallequipmentinthesystemandthepotential hazardsinvolved.Whenriskstopersonsorpropertymay be involved, a holding device must be an integral part of the driven equipment beyond the speed reducer output shaft.Installation, Maintenance and Repair ManualDODGE MAXUM ReducersThese instructions must be read thoroughly before installation or operation.TheDODGEMAXUMreducercanbesuppliedasaseparate reducer with either double or triple reduction gearing. It may also be supplied with a drive motor mounted on a common base with the reducer and connected by means of a fexible coupling. Otherarrangementssuchasascoopmountedmotor,atop mountedmotororanadjustableslidebaseunderthereducer are available. All twelve sizes have a rugged cast iron gear housing with integral feet. All shafts are through hardened.Gearcase covers are accurately located and doweled to the gear housings to assure precise bearing location, minimize distortion and maintain accurate gear alignment. Helical gears and pinions are made from high quality alloy gear steel and are case hardened to provide a durable wear resistant surface. All shafts are through hardened.CAUTION: Instantaneous gear loading is limited to 200% of the reducer rating. Do not allow starting load or other peak loads to exceed this value. Failure to observe this precaution could result in damage to, or destruction of, the equipment.Tapered roller bearings are used exclusively throughout all sizes and ratios. Oil seals are of double lip, spring loaded design to minimize oil seepage and the entrance of contaminants.INSTALLATION INSTRUCTIONSWARNING:Caremustbetakenwhenliftingormovingthe unit. DO NOT attempt to lift the reducer by using a rope, hook or sling attached to the motor, scoop or other accessories. DONOTattempttoliftthereducerbyeyeboltsattached toaconnectedmotor.Reducersshouldbeliftedonlyby slings on input and output shafts on smaller reducers or by liftinglugsprovidedonlargerunits.Wheremorethanone lug is provided a double hook chain or sling must be used to evenly distribute the load. Failure to observe this precaution could result in bodily injury.FoundationThefoundationformountingthereducermustbesuffciently rigidtomaintaincorrectalignmentwiththedrivenequipment. Thefoundationmusthaveafatandlevelmountingsurfaceto assureuniformsupportfortheunit.Fabricatedpedestalsor baseplatesformountingreducersmustbecarefullydesigned toassurethattheyaresuffcientlyrigidtowithstandoperating conditions. (DODGE MAXUM motor base plates and slide bases are fabricated from heavy steel to achieve the necessary rigidity.)CAUTION: The reducer must be mounted on a at base with propershimming.Failuretoobservethisprecautioncould result in damage to, or destruction of, the equipment.2Whenmountingareduceronstructuralsteel,arigidbaseplate is recommended. Bolt the reducer and base plate securely to the steelsupportswithpropershimmingtoensureafatandlevel surface. If the reducer is to be mounted on a concrete foundation, groutsteelmountingpadsintotheconcretebaseratherthan grouting the reducer directly onto the concrete.If the reducer is used with an adjustable slide base, the base must bemountedonthefoundationasrecommendedabove.Lateral adjustment is provided by the adjustment screws in the slide base when a V-belt or chain drive is used.LevelingIf shims are used to level or align the unit or slide base, they must bedistributedevenlyaroundthebaseunderallmountingpads to equalize the load, thus avoiding distortion of the housing and highly localized stresses.Useafeelergaugetodeterminethecorrectthicknessofthe shimsrequired.Allpadsmustbesquarelysupportedwhenthe reducer is secured.AlignmentIfreducerisreceivedmountedonabaseplateorwithamotor scoopmounted,itwasalignedatthefactory.Thepossibility ofmisalignmentintransitmustbecheckedwhenmounting thecompleteunit.Recheckalignmenttodetermineifany misalignment has occurred.If shims are required, they should be placed between the mounting pads and the base plate or between the motor feet and the scoop. Allboltingbetweenthebaseplateandfoundation,motorand scoop must be tight to prevent fatigue.Couplingsmustbealignedsothattheangularalignmentand parallel alignment is within the coupling alignment specifcations withallboltssecured.Aftersatisfactoryalignmentclosethe coupling.NOTE:Pleasefollowtheinstallationinstructionsprovided with each individual coupling.)COUPLINGSHAFT GAPCOUPLING GUARDSHIM ASREQUIREDHD BASE PLATEMOTORREDUCERFigure 1 - Heavy Duty Base PlateCOUPLINGSHAFT GAPCOUPLING GUARDSHIM ASREQUIREDSCOOPMOTORREDUCERFigure 2 - ScoopACCESSORY MOUNTING INSTRUCTIONSWARNING:Theuserisresponsibleforconformingwiththe National Electrical Code and all other applicable local codes. Wiringpractices,grounding,disconnectsandovercurrent protectionareofparticularimportance.Failuretoobserve these precautions could result in severe bodily injury or loss of life.Ifcouplings,sprockets,pinionsorpulleysaretobeinstalledin thefeld,careininstallinganduseofkeyswillpreventcocking ordamagetoshafts.Theseattachmentsshouldnotbedriven orhammeredintoposition,butpreferablyheatedto375Fand slipped onto shafts.Sprockets and pulleys should be mounted as close as possible to gear housings to minimize overhung loads.Top Mounted Motors - Assembly InstructionsRefer to Figure 3 when installing the top motor mount. Also refer to the top motor mount parts guide Figure 18 and Table 31 for parts identifcation. Table 31 also identifes which top mount supports require the use of longer bolts furnished in the top mount kit and which top mount supports use the standard length cover bolts.Figure 3 - Top Motor MountRemovetheupperfourbolts(9)and(11)andlockwashers(10) and(12)fromtheinputandoutputcover.Onthesizes1and2 reducer remove only the upper three bolts and lockwashers from each cover.Installtheoutputendtopmotormountaftsupport(2)tothe reducerusingthecoverboltsorifnecessary,thelongerbolts (9) and the fat washers (10) furnished with the top mount kit and 3tighten the bolts fnger tight. If the cover bolts furnished with the top mount kit are of different lengths, the longer bolts go on the output end in position (9). Do not fully tighten at this time. The top motor mount aft support (2) will be the shorter of the two uprights for the size 7 and larger reducers.Install the input end forward support (1) using the other four cover bolts(11)orifnecessary,thelongerboltsfurnishedwiththekit andthefatwashers(12).Tightentheboltsfngertight.Ontop mounts for the size 7 and larger reducers the forward support (1) will overlap the aft support (2).PlacetheUshapedmotorplate(3)ontopofthesupports(1) and(2)withthelegsoftheUupandwiththeendstamped INPUTENDtowardtheinputshaft.Locatetheslotsthatbest align with the holes in the forward and aft supports. Insert bolts (6), and install washers (7) and nuts (8). Tighten the nuts (8) fnger tight.Now tighten the bolts (9) and (11) holding the aft (2) and forward (1) supports to the reducer. The bolts must be tightened to the torque specifed for that bolt diameter as listed in Table 12.Place the four adjusting screws (5) in the U shaped motor plate (3) and secure with two nuts (13) each.Thread one nut (13) part way down on each adjusting screw (5). Place the fat motor plate (4) over the adjusting screws and thread on the other four nuts (13). The input end of the fat motor plate (4) is the end with the smallest motor holes located closest to the edge. Adjust the nuts (13) until the motor plate is level or parallel to the reducer input shaft.Place the motor on top of the fat motor plate and bolt in place. Tighten these bolts.Slide the motor sheave onto the motor shaft as far as it will go and slide the reducer sheave onto the reducer shaft as far as it will go. Roughly align the sheaves by sliding the U shaped motor plate (3)forwardorbackwardsuntilthesheavesareinapproximate alignment. Tighten the bolts (6) and nuts (8) to their recommended torque as given in Table 12.Alignthesheavesverticallybyplacingastraightedgeacross thefaceofeachsheave.Alignmentshouldberecheckedafter thesheavesarefullytightenedtotheshaftsandreadjustedif necessary.Makesurethatthesheavesremainasfarontotheir shaftsaspossiblesoastominimizebearingloadsonboththe motor and the reducer caused by belt tensions.InstalltheV-beltandproperlytensionthebelts.Theuseofa DODGEV-belttensiontesterwillassistinobtainingtheproper tension.Donotovertensionthebeltswhichwillcauseexcess loadsonthemotorandreducerbearingsnorundertensionthe belts which will cause reduced belt life.Recheckthehorizontalalignmentofthemotorshaftbyplacing astraightedgeacrossthefaceofthemotorsheaveandnoting where it meets the reducer sheave.Adjustthefatmotorplateusingtheforwardandaftadjusting screwsuntilthemotorshaftandthereducershaftareparallel. Recheck belt tension.WARNING:Ensurethatallguardsareproperlyinstalled before proceeding. Exercise extreme care to avoid contacting rotating parts. Failure to observe this precaution could result in severe bodily injury.Installthebeltguard.HolesareprovidedonthesideoftheU shaped motor plate (3) for attachment of the belt guard.Table 1 - Hole Locations for 1-6 MAXUM Side PlatesMAXUM SizeMotor Frame "D" Mounting Holes"U"Design1 AND2 140T3.501 & 2DOWN1 180T4.503 & 4DOWN1 210T5.251 & 2UP1 250T6.253 & 4UP1 3 AND4 140T3.501 & 2DOWN2 180T4.504&5DOWN2 210T5.251 & 2UP2 250T6.254 & 5UP2 280T7.001-3-4UP2 320T8.005-6-7UP2 5 AND6 180T4.501-2-3UP3 210T5.254-5-6UP3 250T6.257-8-9UP3 280T7.0010-11-12UP3 320T8.0013-14-15UP3 360T9.0016-17-18UP3 U UPU DOWNEND VIEW OFBOTTOM PLATED REFERS TO MOTOR SHAFT HEIGHTHOLES SHOWN ARE FOR USE WITHOR WITHOUT AN EXTERNAL BACKSTOPTable 2 - Hole Locations for 7-12 MAXUM Side PlatesMAXUM SizeMotor Frame"D" Mounting Holeswithout BackstopMounting Holeswith BackstopDesign 7 THRU 10 210T5.251-2-320-21-224 250T6.254-5-623-24-254 280T7.007-8-926-27-284 320T8.0010-11-1229-30-314 360T9.0013-14-1532-33-344 400T10.0010-12-16-1729-31-35-364 440T11.0013-15-18-1932-34-37 -384 D C R11 AND 12 280T7.001-2-314-15-165 320T8.004-5-617-18-195 360T9.007-8-920-21-225 400T10.004-6-10-1217-19-23-245 440T11.007-9-11-1320-22-25-265 T C R 11 AND 12280T7.00 31.39-70.6227-28-29 5 86.50-194.614-15-16 320T8.0031.39-70.6230-31-32 5 86.50-194.617-18-19 360T9.0031.39-70.6233-34-35 5 86.50-194.620-21-22 400T10.00 31.39-70.6230-32-36-38 5 86.50-194.617-19-23-24 440T11.00 31.39-70.6233-35-37-39 5 86.50-194.620-22-25-26 U UPEND VIEW OFBOTTOM PLATEFOR MAXUM REDUCERS 7 THRU 12 THE BOTTOM PLATE IS MOUNTED U UP IN ALL CASES4DESIGN 12413DESIGN 2132473613DESIGN 3391518612 2 81417511171316410DESIGN 5DESIGN 524 38 1223 361026 39 1325 37111619222932351518212831343691417202582730331472225283134369121521242730332581114202326293214710133617381935163718Figure 4 - Side Plate Hole LocationsScoops - Assembly InstructionsWARNING:Properguardingformotor,reducercoupling, and the output shaft must be provided by the user. Failure to observe this precaution could result in bodily injury.Refer to Tables 1 and 2 and Figure 4 for the proper orientation (U up or U down) of the bottom plate and the hole combinations used to bolt the side plates to the bottom plate. Also refer to the scoop parts guide Figure 19 and Table 32 for parts identifcation. Table32alsoidentifeswhichscoopsrequiretheuseoflonger cover bolts.Place the left (1) and right (2) side plates and the bottom plate (3) with the U properly oriented in front of the reducer.Determinewhichreducercoverboltsneedtoberemovedfor installationofthesideplates.Removeonlythesecoverbolts oryoumayrupturetheoilsealbetweentheendcoverandthe reducer housing.Install the side plates (1) and (2) onto the reducer using the longer bolts(4)furnishedwiththescoopandthefatwashers(5).Do not fully tighten the bolts at this time as you will need sideways movement to assemble the bottom plate.Usingthebolts(6),washers(7)andnuts(8)furnishedinthe bottom plate carton, bolt the bottom plate to the side plates using the correct bolt hole pattern as determined from Tables 1 or 2. Do not fully tighten the bolts at this time.Lowerthemotorintopositionwith1/4shaftseparation.Adjust the bottom plate until the motor mounting bolts can be inserted throughthemotorfeetandthebottomplate.Tightenthebolts (6)holdingthebottomplatetothesideplatesandthebolts (4)holdingthesideplatestothereducertotherecommended tightening torque as determined from Table 12.Ifafanisusedorifanexternalbackstopisused,itshouldbe installed at this time. Move the motor out of the way and follow the fan or backstop installation instructions.Nowshimandalignthemotorfollowingthecouplingassembly instructionsasaguide.Payparticularattentiontothepreload requirements of PARA-FLEX coupling elements. Install the coupling guard.Fans - Assembly InstructionsRefer to Figure 5 and Table 3 for the proper NA dimension to use in locating the fan hub on the input shaft. Also refer to the fan parts guide Figure 20 and Table 33 for parts identifcation. Table 33 also identifes which kits require longer bolts for the lower two bolts.NAHIGHSPEEDSHAFTFigure 5 - Fan NA DimensionsTable 3 - Fan LocationsMAXUM SIZEFAN NA DIMENSIONDOUBLE TRIPLE31.78-41.78-52.69-62.69-73.75-83.75-93.75-103.752.64 113.752.53 123.752.56 5If auxiliary seals are used, they must be installed before installing the fan. Follow the auxiliary seal assembly instructions.Holdthefancover(1)uptotheinputendofthereducerto determinewhichfourreducercoverboltsmustberemoved. Remove these four bolts and lock washers and save the bolts.Placetheinputshaftkey(9)intheshaftkeywayfushwiththe end of the shaft. Slide the fan (3) onto the input shaft to the NA dimension as listed in Table 3. Tighten the setscrews to the torque as recommended below.Sizes 3 through 6 7-8 Ft-Lbs TorqueSizes 7 through 12 14-16 Ft-Lbs TorqueRotate the fan by hand to check for any interference with the fan blades.Mounttheshroud(2)looselytothecover(1)usingthebolts(7) andwashers(8).Onthosesizeswiththetwosmallcutoutsin the shroud, the cutouts must be oriented towards the top of the reducer.Mount the shroud and cover assembly to the reducer using two of the reducer cover bolts (12) and fat washers (11) removed earlier for the upper two bolts. For the lower two bolts (10), if required, use the two longer bolts furnished with the fan kit and fat washers (11). The two spacers (5) go between the fan cover brackets and thereducercoveratthebottomtwobolts(10)whenascoopis not used. On the MAXUM reducer sizes 3, 4 and 5, four spacers are used when a scoop is not used. If a scoop is used, discard these spacers.Adjust the fan shroud (2) until the radial clearance between the fan hub (3) and the shroud is approximately equal all the way around. The fan shroud should be fush with the end of the fan hub.Tighten the four bolts (7) to the torque values as recommended below.Sizes 3 through 6, 14-17 Ft-Lbs TorqueSizes 7 through 12 27-33 Ft-Lbs TorqueTighten the reducer cover bolts (10) and (12) to their recommended tightening torque as determined from Table 12. Install the button plugs (6) in the top two bolt access holes in the fan shroud and, if necessary, in the access hole for the breather.Auxiliary Seals - Assembly InstructionsAuxiliary seals must be installed before mounting any accessories on the shafts.Refer to Figure 6 and Table 4. Also refer to the auxiliary seal parts guide Figure 21 and Table 34 for parts identifcation.WFigure 6 - Auxiliary Seal Installation WidthRemove the bolts (4) and lock washers (5) holding the seal carrier (3) to the reducer cover. Do not remove seal carrier.Placetheauxiliarysealplate(1)againstthesealcarrierand reinstall the bolts (4) and lock washers (5). Do not fully tighten yet.Equalizetheclearancebetweenthesealplateandtheshaftby moving the seal plate through its bolt hole clearance.Tighten the seal carrier bolts (4) to their recommended torque as determined in Table 12.ProtecttheshaftkeyseatwithtapeandtheninstalltheV-ring seal (2) with the V lip against the auxiliary seal plate.Adjust the location of the V-ring seal on the shaft until the ftted widthWisinaccordancewiththedimensionandtolerance found in Table 4. See Figure 6.Table 4 - V-RIng Auxiliary Seals Assembled WidthsMAXUM SIZEINPUT SHAFT SEAL OUTPUT SHAFT SEAL WIDTH W TOLERANCE WIDTH W TOLERANCE10.350.030.430.04 20.350.030.430.04 30.430.040.430.04 40.430.040.530.05 50.430.040.530.05 60.430.040.530.05 70.430.040.530.05 80.530.050.610.06 90.530.050.610.06 100.530.050.610.06 110.530.050.710.07 120.530.050.710.07 NOTE: Tolerance is + or - inches.Slide Bases - Assembly InstructionsRefer to Figure 7. Also refer to the slide base parts guide Figure 22 and Table 35 for parts identifcation.13, 4, 5, 62Figure 7 - Slide BaseThe MAXUM reducer slide base positions the reducer, providing simplifed installation of belt and chain drives.The slide base (1) should be installed on a fat and level surface. Iftheslidebaseisinstalledonaconcretefoundation,steel mountingpadsshouldbegroutedintotheconcreteateachof thefourfoundationmountingholes.Theslidebaseshouldbe shimmed until the top surface is fat where the reducer mounts. Mount the reducer to the slide base using the four mounting bolts (3), a fat washer (4) on top of the reducer foot and a lock washer 6(5) and nut (6) underneath the slide base. Adjust the belt or chain tensionusingtheadjustingscrews(2)andtightenthereducer holddown bolts (3) to the torque value given in Table 13.Whenachangeinreducerpositionisdesired,simplyloosen thereducerhold-downbolts(3)andslidethereducerbyusing the adjusting screws (2) provided. After the desired belt or chain tension has been obtained, retighten the reducer bolts (3) to the torque value given in Table 13 and the unit is ready to operate.Heat ExchangersReducers supplied with water cooled heat exchangers, Figure 8, shouldbepipedtothecoolingwaterlinesandcorrectfowof coolant observed. Control devices should be wired and checked for correct operation. Check pipes periodically for sediment build up from the water. Clean if necessary.OILPOUTH-EWATERINFigure 8 - Heat ExchangerDODGE MAXUM Medium Duty BaseplatesMediumdutybaseplates,Figure9,arerigidunitsfabricatedof steel, providing a sturdy cross-braced mounting base for support of medium duty AC or DC motors weighing less than the reducer or less than 700 lbs.Figure 9 - Medium Duty Base PlateDODGE MAXUM Heavy Duty BaseplatesHeavydutybaseplates,Figure10,arerigidunitsfabricated ofsteel,providingasturdymountingbaseformotorcoupling/reducer combinations. This accessory is recommended for large motors,wherethemotorweightexceedsthereducerweight or700Ibs.andforallvariablespeedDCorACapplications regardless of the motor weight.Figure 10 - Heavy Duty Base PlateMAXUM Coupling GuardsMAXUMcouplingguards,Figure11,offabricatedsteelare availableforusewithcoupledinputshaftsofMAXUMreducer sizes1through12.Theyofferprotectiontopersonnelfrom contactwithrotatingpartsandfromobjectsfallingintothe rotating coupling.Figure 11 - Coupling GuardBackstops - Assembly InstructionsWARNING:Donotusebackstopsforapplicationsinvolving energyabsorptionandshockortorqueloadsinexcessof reducerratingsnoronapplicationssuchaschairlifts, amusementrides,etc.,andwherethesafetyofpersonor propertyisdependentontheirfunction.Failuretoobserve this precaution could result in bodily injury.Figure 12 - External BackstopA backstop, Figure 12, can be furnished on all DODGE MAXUM reducers.Thebackstopisusedwhenapplicationsrequireone direction of rotation or holding.AnexternalbackstopisusedonallsizesofMAXUMreducers. On sizes 7 through 12, a special diameter and length input shaft is required. For correct lengths and diameters, consult the factory before installing.Note that backstops are not compatible with all accessory items. Backstopscannotbeusedinconjunctionwithfansonreducer sizes 3 through 7 and backstops cannot be used in conjunction with top motor mounts on reducer sizes 7 through 12.Backstops installed on reducers shipped from the factory should becheckedfortheproperdirectionofrotationbeforestartup. Turntheinputshaftbyhandtodetermineifthedirectionof 7rotation is correct. If rotation is incorrect, the backstop must be reversed.Forinstallationorreversalofbackstops,locatethe correct instructions for your size reducer in the following data.General Information1.Do not use the backstop above its torque or speed ratings.2.DO NOT ATTEMPT TO TAKE THE BACKSTOP APART. It is a precisionmechanismmadebyexperiencedworkersunder high quality control standards.WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Failuretoobservethisprecautioncouldresultinbodily injury.WARNING:Ifbackstopisusedtorestrainaload(likean inclinedconveyor),blockthemachinerysoitwillnotmove priortoproceedingwithbackstopremoval.Failureto observe this precaution could result in bodily injury.Installation Instructions For Backstop Sizes 1-6Followthedetailedinstallationinstructionsincludedwiththe backstop.Installation Instructions For Backstop Sizes 7-12Refer to the backstop parts guide Figure 23 and Table 37 for parts identifcation.1.Itisimportantthatthebackstopfttheshaftproperly.The external backstops (1) should be mounted on the high speed shaft (23) of MAXUM reducers with a clearance ft of 0.001 to 0.003 inches.CAUTION:Onapplicationswhereapresstisnecessary, consult the factory. Failure to observe this precaution could result in damage to or destruction of the equipment.2.To minimize critical stresses in the keyway area of the inner race, the backstop keyways have a radius in the corners. A hardened key (4) designed to match the keyway is furnished witheachstockbackstop.Usethiskeyinmountingthe backstoptotheshaft.Thekeymustbe40RockwellC minimumhardnessandmustbecompletelycontained under the backstop inner race. A tight ft on the key width is necessary on indexing applications.3.Orientthebackstop(1)asthoughinoperatingpositionand check for proper rotation.4.On those backstops designed as shown in Figure 23b, attach the torque-arm angle (12) to the torque-arm (11) using bolts (13),washers(14)(15)andnuts(16).Tightento59-67foot pounds torque.Attach the torque arm (11) to the backstop (1) using the screws (7) and lock washers (8). Torque to the values in Table 5.Table 5 - Torque ValuesScrew SizeTorque Value 5/16-24 UNRF220 inch-Ibs 3/8-24 UNRF400 inch-Ibs 1/2-20 UNRF1000 inch Ibs CAUTION:NEVERUSETHEBACKSTOPASACOUPLING. When the connection of two shafts is required in conjunction withabackstop,useacoupling.Failuretoobservethis precaution could result in damage to, or destruction of, this equipment.5.Removethetwoinputcoverboltsandlockwashers(12) from the reducer which align with the clearance holes in the backstop torque-arm (11) or torque-arm angle (12). Save the lockwashers.6.Insert the two studs (10) into the reducer cover bolt holes as far as they will go and thread on the nuts (9) and lock washers (12). Tighten the nuts to the torque specifed in Table 12.7.Place the backstop key (4) into the input shaft (23) keyway.8.Line up the keyways between the backstop and the reducer housing by rotating the input shaft in the opposite direction of its driving direction. If the backstop is properly oriented, the entire backstop will rotate with the input shaft in this opposite direction.9.Slide the backstop onto the input shaft and over the backstop key until the backstop inner race is against the shoulder on the shaft. The studs (10) must completely penetrate the two holesinthebackstoptorquearmandthetorquearmmust not bind up on the studs.10.Whenmountingthebackstopontheshaft,applypressure totheendfaceoftheinnerraceonly,asbearingdamage couldresultfrompressurebeingappliedtotheouterrace. Care should also be exercised when installing the backstop to prevent damage to the seals.11.Secure the backstop in position by sliding the retaining collar (5)ontotheshaftandupagainstthebackstopinnerrace. Tighten each of the three setscrews (6) in the retaining collar to 87 inch-Ibs.12.Overrun (freewheel) the backstop by hand before subjecting it to test operation. Check to make sure the torque arm is not binding on the studs (10).13.Fill the backstop with Exxon Beacon 325.Backstop Lubrication for MAXUM Sizes 7-121.Proper lubrication is critical to the extended service life of the external backstop.CAUTION:LubricantclassesEP(extremepressure)MUST NOT be used in backstops. Failure to observe this precaution could result in damage to or destruction of the equipment.2.Thegreaselubricatedbackstopsarepackedatthefactory with Exxon Beacon 325.3.Forstandardbackstopswithlabyrinthseals,pumpgrease intothebackstopuntilitfowsfreelyfromtheseals.Use Exxon Beacon 325 grease.4.Lubricate the backstop every three months. If the backstop is operating under severe abrasive dust conditions or twenty four hours daily, lubricate monthly. Use Exxon Beacon 325.GUIDELINES FOR GEAR REDUCER LONG-TERM STORAGEDuringperiodsoflongstorage,orwhenwaitingfordeliveryor installationofotherequipment,specialcareshouldbetakento protect a gear reducer to have it ready to be in the best possible 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 greatly reduced. The following precautions will protect gear reducers during periods of extended storage:Preparation1.Draintheoilfromtheunit.Addavaporphasecorrosion inhibiting oil. (VCI-105 oil by Daubert Chemical Co.) Refer to Table 6 for the correct quantity.2.Seal the unit air tight. Replace the vent plug with a standard pipe plug and wire the vent to the unit.83.Covertheshaftextensionwithawaxyrustpreventive 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.Protectthereducerfromdust,moisture,andother contaminantsbystoringtheunitinadryarea.Maintaining thestorageareaataconstanttemperaturewillreduce condensation in and on the reducer.Table 6 - MAXUM Quantities of VCI #105 Oil for Long-Term StorageMAXUMQUARTS OR LITERS 1.1 2.1 3.2 4.2 5.3 6.4 7.9 81.2 91.5 101.7 6.In damp environments, the reducer should be packed inside amoisture-proofcontaineroranenvelopeofpolyethylene containing a desiccant material. If the reducer is to be stored outdoors, cover the entire exterior with a rust preventive.When placing the reducer into service1.Assemble the vent plug into the proper hole.2.Clean the shaft extensions.3.Check the reducer for condensation.4.Filltheunittotheproperoillevelusingarecommended lubricant. The VCI oil will not affect the new lubricant.5.Follow the installation instructions provided with the unit. REDUCER START-UP INSTRUCTIONSWARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Failuretoobservethisprecautioncouldresultinbodily injury.Before starting, check the diagrams in this manual to see that the oil level plug is correctly positioned. When the unit is mounted in a position other than shown, consult factory.OperateonlyatHP,speedandratioshownonthenameplate. Before changing any of these, consult factory for correct oil level, parts and application approval.When starting up a new DODGE MAXUM reducer, we recommend the following procedures be followed:Checklist1.Hasthemotor/reducercouplingbeencheckedforproper position and alignment?2.Check all mounting bolts, screws, accessories, etc. to make sure they have not loosened in shipping.3.Has lubricant been added to reducer, is it of proper viscosity and to correct level?4.Has backstop rotation been checked?5.Are all electrical connections made and insulated?6.Are all safety guards in place and properly installed?Ifthereducerisequippedwithawater-cooledheatexchanger, make sure that clean cooling water is fowing to the oil cooler. Coolingwatershouldnotexceed80Fonentryintothecooler unless the cooler was selected for higher water temperature.To avoid damage to the motor or backstop used with a DODGE MAXUMreducer(havingabackstop),breakthehighspeed couplingconnection,turninputshaftbyhandtocheckproper rotation. Operate motor to check shaft rotation, reversing leads if necessary to secure proper rotation. Then reconnect the coupling.Theelectricmotororprimemoverstartingequipmentshould bearrangedtostartthereducerslowlytoavoidsevereshock. Acrossthelinestartingofmotorsshouldbeusedwithcareto preventinstantgearloadinginexcessof200%ofthereducer rating.Bring motor and reducer up to normal operating speed, continuing to check for excessive vibration, unusual sounds, excessive heat or oil leakage. If any of these conditions develop, the unit should be immediately shut down the cause determined and corrected.The reducer should be operated at about 1/2 load for 8 hours to allow run in of gears. After this period, the unit can be operated at full load.REDUCER LUBRICATION INSTRUCTIONSWARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Failuretoobservethisprecautioncouldresultinbodily injury.Lubrication is extremely important for satisfactory operation. The proper oil level, Table 9, must be maintained at all times. Frequent inspections with the unit not running and allowing suffcient time fortheoiltocoolandtheentrappedairtosettleoutoftheoil, shouldbemadebyremovinglevelplugtoseethatthelevelis beingmaintained.Iflow,addthepropertypeandviscosityof lubricant through one of the upper openings until it comes out of the oil level hole. Replace the oil level plug securely.Afteraninitialoperationofabouttwoweeks,theoilshouldbe changed. If desired, this oil may be fltered and reused. Very often, smallmetalparticleswillshowupintheoilduetothewearing-inprocess.Aftertheinitialbreak-inperiod,lubricantshouldbe drained,magneticdrainplugcleaned,gearcasefushedand reflledevery2500hoursofoperationunderaverageindustrial conditions; more frequently when running continuously or at high temperatures.UseonlyrecommendedlubricantsfromTables7 or 8 or equivalent. Special attention should be given to checking of lubricants when any of the following conditions exist:1.High operating temperatures resulting from heavy intermittent loads, causing the temperature of the gearcase to rise rapidly and then cool.2.Unusualambientconditionswhichmaytendtocause condensationontheinsideofthegearcasethereby contaminating the oil.3.Operating temperatures that would cause oil to remain above 180F continually.4.Ifthereducerissubjectedtounusualvaporsormoist atmosphere.9Operating TemperaturesHeatingisanaturalcharacteristicofhighspeedgearing, andamaximumgearcasetemperatureapproaching200Fis notuncommonforsomeunitsoperatinginnormalambient temperatures(80F).Whenoperatedatratedcapacity,no damagewillresultfromthistemperatureasthiswastakeninto consideration in the design of the gearcase and in the selection of the lubricants.Gearcase VentCare should be taken to prevent any foreign matter from entering thegearreducer.Properandadequatelubricationishindered when dust, dirt, moisture and chemical fumes are allowed to enter the reducer. Baldor Electric Company should always be advised prior to order entry of any special environmental conditions.The vent plug is designed to prevent dirt and water from entering thegearcaseandalsoreleaseairpressurecausedbyheat generated in the gearcase. Without proper air venting the increase in air pressure may force lubricant through the oil seals and result in oil seal leakage and damage to the oil seal. Do not restrict the operation of the vent with paint or other obstructions.Preventive MaintenanceThe instructions for oil changes should be followed.Afterthefrstweekofoperation,allexternalhousingandhold downboltsshouldbecheckedandtightenedifnecessary.All oil level and drain plugs should also be tightened if necessary. It is recommended the alignment be checked between motor and reducer and reducer to driven machine after two to three weeks of operation.Dailyroutinevisualinspectionsshouldbemadeforoilleaksor anyunusualsounds.Ifeitherconditionexists,theequipment should be shut down and corrective measures taken.Weekly - Check oil level and add if required.Monthly - Check oil for any signs of contamination.LALB VDL = LEVEL PLUGD = DRAIN PLUGV = VENT PLUGFigure 13 - Oil Level Locations for Position A-1 ISO VISCOSITYTable 7 - Lubrication RecommendationsISO Grades for Ambient Temperatures of 50 thru 125FOUTPUT RPM REDUCER SIZE 123456 7 89101112 230220220220220220220220220220220220220 190320320220220220220220220220220220220 155320320320220220220220220220220220220 125320320320320320220220220220220220220 100320320320320320320220220220220220220 84320320320320320320220220220220220220 68320320320320320320320320220220220220 56320320320320320320320320320320320220 45320320320320320320320320320320320320 NOTES:1. Use ISO 220 above 230 output RPM.2. Use ISO 320 below 45 output RPM.3. Assumes auxiliary cooling where recommended in the catalog. Table 8 - Lubrication RecommendationsISO Grades for Ambient Temperatures of 15 thru 60FOUTPUT RPM REDUCER SIZE 123456 7 89101112 230150150150150150150150150150150150150 190220220150150150150150150150150150150 155220220220150150150150150150150150150 125220220220220220150150150150150150150 100220220220220220220150150150150150150 84220220220220220220150150150150150150 68220220220220220220220220150150150150 56220220220220220220220220220220220150 45220220220220220220220220220220220220 NOTES:1. Use ISO 150 above 230 output RPM.2. Use ISO 220 below 45 output RPM.3. Assumes auxiliary cooling where recommended in the catalog.10CLASSIFICATION SYSTEMAllindustrialoilsaregradedaccordingtotheISOViscosity ClassifcationSystem,approvedbytheInternationalStandard Organizations(ISO).EachISOviscositygradenumber correspondstothemid-pointofviscosityrangeexpressedin centistokes(cSt)at40C.Forexample,alubricantwithanISO gradeof32hasaviscositywithintherangeof28.8-35.2,the midpoint of which is 32.RuleofThumb:ThecomparableISOgradeofacompetitive productwhoseviscosityinSUSat100Fisknowncanbe determined by using the following conversion formula:SUS @ 100F 5 = cSt @ 40CUse industrial oils with rust and oxidation inhibitors and anti-foam additives. See Figure 14.Table 9 - Approximate Oil Capacities and Oil Levels* vs Output RPMsMAXUM Size (See Note) OutputRPMApproximate OilCapacity (Quarts)LevelPosition MAXUM Size(See Note) OutputRPM Approximate OilCapacity(Gallons)LevelPosition 1Above 3752.8L-A 7 Above 1758.3 L-A Below 3755.2L-BBelow 17517.6 L-B 2Above 3554.1L-A 8 Above 16010.7L-A Below 3557.3L-BBelow 16020.9L-B 3Above 3006.5L-A 9 Above 14012.6L-A Below 30012.0L-BBelow 14027.2L-B 4Above 2709.0L-A 10Above 12012.9L-A Below 27016.6 L-BBelow 12029.8L-B 5Above 25010.9 L-A 11 Above 11016.3L-A Below 25021.2L-BBelow 11036.9L-B 6Above 21515.7L-A 12 Above 9520.0L-A Below 21530.7L-BBelow 9542.5L-B * Always ll to the oil plug regardless of the stated quantities.NOTE: For variable speed applications, use the oil level for the lowestoperating speed or refer to DODGE for specic recommendations for your application.11 OIL VISCOSITY EQUIVALENCY CHART 20001000800600500400300200100806050403020108654327060504030201085497615001000680460320220150100688A876543285W2501409080W463222151075175W32300200150100807060504035324005006008001000150020003000400050006000800010,000cSt/40C 100CcSt/ ISOVGAGMAGRADESGRADESGEAR OILSSUS/100FSUS/210FSAEKINEMATICVISCOSITIESSAYBOLTVISCOSITIES2003001009080706055504540VISCOSITIES CAN BERELATED HORIZONTALLYONLY.VISCOSITIES BASED ON96 VI SINGLE GRADEOILS.ISO ARE SPECIFIED AT40C.AGMA ARE SPECIFIED AT40C.SAE 75W, 80W, AND 85WSPECIFIED AT LOWTEMPERATURE.EQUIVALENTVISCOSITIES FOR 100FAND 200F ARE SHOWN.SAE 90 TO 250 SPECIFIEDAT 100C.Figure 14 - Viscosity Classication Equivalents12TROUBLESHOOTING GUIDEWARNING: Subsequent steps may require rotating parts to be exposed. Stay clear if unit must be running or disconnectand lock out or tag power source if contact must be made. Failure to observe these precautions could result in bodily injury.TroubleWhat To InspectAction Overheating 1. Unit overloaded 2. Oil cooler operation 3. Has recommended oil level been exceeded or is level too low? 4. Are bearings properly adjusted? 5. Breather 6. Grade of oil 7. Coupling lateral oat 8. Is reducer covered with dirt? 9. Is free air ow around reducer restricted? 10. Is fan intake choked? Reduce the loading or replace with drive of sufcient capacity. Check coolant and oil ow. Vent system of air. Oil temperatures into unit should be approximately 100F. Check cooler internally for build up of deposits from coolant water. Check oil level indicator to see that housing is accurately lled with lubricant to the specied level. Bearings must not be pinched. Adjustable tapered bearings must be set at proper bearing lateral clearance. All shafts should spin freely when disconnected from load. Breather should be open and clean. Clean breather regularly in a solvent. Oil must be of grade specied in lubrication instructions. If it is not, clean unit and rell with correct grade.Adjust space between drive motor etc., to eliminate end pressure on shafts. Replace exible coupling with type allowing required lateral oat. Remove dirt which acts as an insulator from reducer. Remove restrictions to free air ow. Clean air intake and check cleanliness under fan guard. Shaft Failure1. Type of coupling used 2. Coupling alignment 3. Is overhung load excessive? 4. Is unit subjected to high energy loads or extreme repetitive shocks? 5. Are V-belts over-tensioned? Rigid couplings between rigidly supported shafts can cause shaft failure.Replace with coupling to provide required exibility and lateral oat. Realign equipment as required. Reduce overhung load. Use outboard bearing or replace with unit having sufcient capacity. Apply couplings capable of absorbing shocks and if necessary, replace with drive of sufcient capacity to withstand shock loads. Check belt tension with DODGE belt tension checker.Improper V-belt tension can cause excessive belt wear if too loose or shaft and bearing failures if too tight. Bearing Failure1. Is unit overloaded? 2. Is overhung load excessive? 3. Are bearings properly adjusted? 4. Are bearings properly lubricated? 5. Rust formation due to entrance of water or humidity.6. Has unit been stored improperly or damaged by prolonged shut-down?7. Are V-belts over-tensioned? See -overheating (item 1). Abnormal loading results in aking cracks and fractures of the bearing. Seeshaft failures (Item 3). Seeoverheating (Item 4). If bearing is too free or not square with axis, erratic wear pattern will appear in bearing races. Improper lubrication causes excessive wear and discoloration of bearing. Make necessary provisions to prevent entrance of water. Use lubricant with good rust inhibiting properties. Make sure bearings are covered with sufcient lubricant. Rotate gear unit more frequently during prolonged shut-down periods.Prolonged periods of storage in moist, ambient temperatures will cause destructive rusting of bearings and gears. When these are found to have existed, the unit must be disassembled, inspected and damaged parts either thoroughly cleaned of rust or replaced.Seeshaft failures (Item 5).13TROUBLESHOOTING GUIDEWARNING: Subsequent steps may require rotating parts to be exposed. Stay clear if unit must be running or disconnectand lock out or tag power source if contact must be made. Failure to observe these precautions could result in bodily injury.TroubleWhat To InspectAction Oil Leakage1. Has recommended oil level been exceeded? 2. Is breather open? 3. Oil seals 4. Plugs at drains, levels, etc. and standard pipe ttings? 5. Housing and caps Check to be sure oil level is accurate at level indicated on housing. Breather should be open and clean. Check oil seals and replace if worn. Check condition of shaft under seal and polish if necessary. Slight leakage is normal and required to minimize friction and heat. Apply sealant, and tighten ttings. Tighten cap screws or bolts. If not entirely effective, remove housing cover and caps. Clean mating surfaces and apply new sealing compound. Reassemble. Check compression joints by tightening fasteners rmly. Noise1. Unusual or increasing noiseSeegear wear and bearing failure. 14Table 10 - MAXUM Reducer Bearing End Play SpecicationsMAXUM SIZEINPUT SHAFT (23)C/S PINION SHAFT (24)LOW SPEED PINION (30)OUTPUT SHAFT (32) 1.003-.005.001-.003.001-.003.001-.003 2.003-.005.001-.003.001-.003.001-.003 3.003-.005.001-.003.001-.003.001-.003 4.004-.006.001-.003.001-.003.001-.003 5.005-.007.001-.003.001-.003.001-.003 6.005-.007.001-.003.001-.003.001-.003 7 .005-.007.007-.009 * .001-.003.001.003.001.003 8 .005-.007.007-.009 * .001-.003.001-.003.001-.003 9 .005-.007.007-.009 * .001-.003.001-.003.001-.003 10 .005-.007.007-.009 * .001-.003.001-.003.001.003 11 .005-.007.007-.009 * .001-.003.001-.003.001-.003 12 .005-.007.007-.009 * .001-.003.001-.003.001-.003 * Use the larger cold end-play setting for reducers with an external backstop.Table 11 - Metric Bolt Usage Bolt Size vs Location for ReducersMAXUM SIZE INPUT SEAL CARRIER LOC (45) OUTPUT SEAL CARRIER LOC (47) INPUT COVER LOC (49) OUTPUT COVER LOC (51) BEARING CARRIER LOC (53) C/S BEARING RETAINER LOC (55) LS PINION RETAINER LOC (57) LS PINION COVER LOC (59) 1M8M10M10M10M10M8M8-2M8M10M10M10M10M8M8-3M8M10M12M12M12M8M8-4 M8 M10M12M12M12M8M8-5M10M10M12M12M12M8M8-6M10M12M12M12M12M8M10-7 M12 M12M16M16M12M8M12M8 8M12M12M16M16M12M8M12M8 9M12M16M16M16M16M10M12M8 10 M12 M16M20M20M20M12M12M8 11 M12 M20M24M24M24M12M16M8 12 M12 M20M24M24M24M12M16M8 Table 12 - Tightening Torque Values Metric Grade 8.8 BoltsBOLT SIZE TORQUE VALUEFT-LBM54-5 M67-8 M817-19 M1034-38 M1259-67 M16145-165 M20285-325 M24485-560 15Table 13 - Tightening Torque Values SAE Grade 5 BoltsBOLT SIZE TORQUE VALUE FT-LB3/820-23 7/1630-35 1/248-55 5/895-110 3/4175-200 7/8270-320 1410-480 1-1/8510-590 1-1/4730-840 1-3/8950-1100 1-1/21260-1460 1-3/41600-1850 Table 14 - Tightening Torque Values Pinion ESNA NutsMAXUM SIZE C/S PINION (27) THREAD SIZE TORQUE VALUE FT-LBLOW PINION (30) THREAD SIZE SPEED TORQUE VALUE FT-LB15/815 -231150-225 25/815 -231150-225 31150 -2251150-225 41150 -2251150-225 51150 -2251-1/4170-255 61150 -2251-1/4170-255 71-1/4170 -2551-3/4310-465 81-1/4170 -2551-3/4310-465 91-1/4170 -2551-3/4310-465 101-3/4310 -4652-1/4690-1035 111-3/4310 -4652-1/4690-1035 122-1/4690 -10352-1/4690-1035 NOTE: Torque values are in foot-pounds.Special InstructionsBecauseofthewiderangeofDODGEMAXUMreducersizes, there will be a need for larger tools and equipment. Normal tools canbeusedonmostsmallerreducersizes.Whenrepairsare required on larger reducers there will be a need for crane facilities to enable movement of complete unit as well as removal of covers andshafts.Hardwareislargerandspeciallytorqued;causing therefore, the need for large torque wrenches and sockets. Where ESNA nuts are used to secure gears to shafts, a strap wrench is helpful to hold a shaft while removing the nut.GENERAL DISASSEMBLY PROCEDUREWARNING:Equipmentbeingremovedmaybetooheavyto controlmanually.Supportitbyexternalmeans.Failureto observe these precautions could result in bodily injury.Refer to the double and triple reduction parts drawings Figures 15, 16 and 17 for the location of the parts referred to in the brackets ( ). Since MAXUM reducers use standard metric hardware, refer to Table 10 for a listing of the metric bolt sizes used and therefore the sizes of sockets and wrenches required. The ESNA nuts listed in Table 14 require English series sockets.With medium or larger units, disassembly must be performed with the reducer input shaft positioned vertically and a hoist available.1.Before disassembly - oil must be drained and all accessories must be removed.2.Begin disassembly at the input end by positioning the reducer with the input shaft vertical.3.Remove the bolts (45) from the input seal carrier (7). Tap the seal carrier with a mallet to loosen the sealed joint. Remove the seal carrier with the oil seal. It is recommended that new oil seals be used at reassembly; but, if the old oil seals must bereused,thencovertheinputshaftkeywaywithplastic electricaltapetopreventtheedgesofthekeywayfrom cuttingthelipoftheseal.Thetaperedrollerbearingshims (13) can now be removed.4.Removethehexheadcapscrews(49)whichsecurethe inputcover(4)tothehousing(1or2).AllsizesofMAXUM reducersusetaperedrollerbearingsthroughout.Allcovers are dowelled to the housing and have tapped threaded holes either over the dowel or close to the dowel. Insert the cover bolts(49)removedearlierintothesethreadedjackscrew holes and alternately tighten each bolt until the cover sealed joint is broken and the cover can be removed.5.If this is a double reduction reducer, go to step 9. If this is a triple reduction reducer, continue with step 6.6.Remove the ESNA nut (39) securing the high speed gear (28). Awheelpullerwillberequiredtoremovethegearfromits shaft.7.The bearing carrier (5) is also dowelled for proper alignment. Removethehexheadcapscrews(53)holdingthebearing carriertothehousing.Tapthesideofthebearingcarrier with a mallet to loosen it and at the same time pull out on it. The size 7 and larger reducers have tapped jack screw holes inthebearingcarriertoassistinlooseningthemfromthe housing.8.Withthebearingcarrierremoved,thecountershaftpinion (27) can be lifted out.9.Remove the ESNA nut (41) which is holding the change gear (29) onto the low speed pinion (30). The change gear can now beremoved.Awheelpullerwillberequiredtoremovethe changegearfromitsshaft.Removethelowspeedpinion changegearkey(35)fromthelowspeedpinionshaft.All parts have now been removed from the high speed end of the gearcaseexceptforthelowspeedpinionbearingretainer (8).10.Reposition the reducer with the output shaft vertical.11.Remove the bolts (47) from the output seal carrier (6). Tap the seal carrier with a mallet to loosen the sealed joint. Remove the seal carrier with the oil seal. It is recommended that new oil seals be used at reassembly but, if the old oil seals must bereused,thencovertheoutputshaftkeywaywithplastic electricaltapetopreventtheedgesofthekeywayfrom cuttingthelipoftheseal.Thetaperedrollerbearingshims (16) can now be removed.1612.Removethehexheadcapscrews(51)whichsecurethe output cover (3) to the housing. Insert the cap screws into the jackscrewholesandalternativelytighteneachjackscrew until the sealed joint is broken and the cover can be removed.13.Screwa1/2-13UNCeyeboltintotheendoftheoutput shaft (32) for handling purposes. Slowly lift the output shaft assembly out of the housing taking care to avoid damaging either the low speed gear (31) or the low speed pinion (30).14.Thelowspeedpinionassembly(30)cannowberemoved from the housing.15.Remove the countershaft pinion bearing retainer (11) from the bearing carrier (5) and the low speed pinion bearing retainer (8)fromtheinputendofthehousing.Thetaperedroller bearing shims (14 and 15) can now be removed.16.With all parts removed, the gear case and parts can now be cleaned and inspected.17.Ifthepartsaretobestoredforanylengthoftime,even overnight,theyshouldbecoatedwitharustpreventiveoil and protected against dust and dirt.GENERAL REASSEMBLY PROCEDUREWARNING:Equipmentbeingremovedmaybetooheavyto controlmanually.Supportitbyexternalmeans.Failureto observe these precautions could result in bodily injury.Refer to the double and triple reduction parts drawings, Figures 15, 16 and 17, for the location of the parts referred to in the brackets ( ). Since MAXUM reducers use standard metric hardware, refer to Table 11 for a listing of the metric bolt sizes used and therefore the sizes of sockets and wrenches required. The ESNA nuts listed in Table 14 require English series sockets.Before reassembly, inspect all parts for damage such as nicks or rust and for cleanliness. Pay particular attention to the removal of allsealantsfromallsurfacesandtothecleanlinessofalldowel pin holes.1.Beginreassemblyattheoutputendofthereducerbyfrst looselyinstallingthelowspeedpinionbearingretainer(8) withoutanyshimsandwitheachlowspeedpinionretainer bolt(57)backedoutapproximately3/16.Nowstandthe housing on end with the output end up.2.Install the output bearing-B cup (63) in its housing bore. Be certain that the cup is frmly seated back against its shoulder. Install the low speed pinion bearing-B cup (79) in its bore in thehousingandupagainstthelooselyinstalledlowspeed pinion bearing retainer (8).3.Setthelowspeedpinion(30)subassemblywithitsbearing cones (78 and 80) in its bore. Be careful to avoid nicking the bearing cup or cones.4.Attach a 1/2-13 UNC eye bolt to the end of the output shaft (32). Lower the output shaft subassembly with its low speed gear (31) and bearing cones (62 and 64) into place. Again be careful to avoid nicking any of the bearings or gear teeth. The low speed pinion assembly will have to be tipped out of the waysothatthegearteethcanclearthelowspeedpinion bearing-A cone (78).5.Assemblethelowspeedbearing-Acup(77)intotheoutput cover (3).6.Apply a 1/8 diameter bead of RTV732 silicone sealer to the outputendofthehousing.Thebeadshouldbecontinuous and should be to the inside of all bolt and dowel pin holes.7.Installtheoutputcover(3)onthehousing.Thecoveris dowelled to the housing to assure precise shaft and bearing alignment.ForMAXUMsizes1through6,thecovershould be ftted over the straight dowel pins (83) which will be tightly fttedintothehousing.MAXUMreducerssize7through12 usefourtapereddowelpins.OnMAXUMreducerssize7 through 12 insert the dowel pins into their holes and tap them gently to align the dowel pin holes. Install the bolts (51) and washers(52).Slightlytightenoneboltneareachdowelpin andagaintapeachdowelpinintoplacetocreatethefnal alignment.Tightentheoutputcoverbolts(51)tothetorque value found in Table 12.8.Place the output bearing-A cup (61) into the output cover.9.Using the output seal carrier shims (16) and the output seal carrier(6),shimtheoutputshaftassemblytotheendplay valuespecifedinTable10addingordeletingshimsas necessary.Theoutputshaftshouldberotatedbackand forth while pulling and pushing on the shaft to assure that the rollers are fully seated in the cups and cones and a true end play reading is taken.10.Remove the seal carrier (6). Coat the outside diameter of the output seal (43) with a sealant and press it into the seal carrier withthespringloadedliptowardtheinsideofthereducer. Grease the seal lips.11.Cover the output shaft keyway with plastic electrical tape and lightly grease the shaft and the tape.12.Place the shims from step 9 over the lip of the seal carrier and aligntheboltholes.Applya1/8diameterbeadofRTV732 around the lip of the seal carrier and up against the shims.13.Slide the seal carrier with the shims and seal over the output shaft taking care to avoid cutting the seal on the output shaft keyway.Installthebolts(47)andwashers(48)andtighten the output seal carrier bolts to the torque value specifed in Table 12.14.Turn the reducer over so that the input end is facing up.15.Set the end play on the low speed pinion (30) by placing the proper number of shims (15) between the housing (1 or 2) and the low speed pinion bearing retainer (8). Follow the shimming procedure outlined in step 9. The end play value is specifed inTable10.Installthelowspeedpinionretainerbolts(57) andwashers(58)andtorquetheboltstothetorquevalue specifed in Table 12. The output end is now assembled.16.If this is a double reduction reducer, continue with step 17. If this is a triple reduction reducer, skip to step 23.17.Install the input double bearing-B cup (67) in its housing bore making certain that it is fully seated against its shoulder. The doublereductioninputshaftboreistheborethatisinline with the output shaft.18.Slidethelowspeedpinionspacer(10)ontothelowspeed pinion (30). The end of the spacer with the large chamfer on the outside diameter must go up against the bearing. Insert thehardenedlowspeedpinionchangegearkey(35)inits keyway and up against the spacer.19.Stand the input pinion assembly (23) up in the housing.20.Assemblethechangegear(29)ontothelowspeedpinion shaft.Thepartnumberstampedonthefaceofthegear should be facing you. For ease of installation, heat the gear to 300F. You may have to lean the input pinion out of the way until the change gear teeth have cleared the pinion shoulder.21.Securethechangegear(29)tothelowspeedpinion(30) using the low speed pinion change gear washer (40) and the low speed pinion ESNA nut (41). Tighten the ESNA nut to the torque value given in Table 14.22.If this is a double reduction reducer, skip to step 35.23.Install the counter shaft bearing-A cup (73) in its bore in the housingtakingcaretobesureitisfullyseatedagainstits shoulder. The counter shaft bore is the bore that is not in line with the output shaft bore.24.Slidethelowspeedpinionspacer(10)ontothelowspeed pinion (30). The end of the spacer with the large chamfer on the outside diameter must go up against the bearing. For ease of installation, heat the spacer to 300F. Insert the hardened low speed pinion change gear key (35) in its keyway and up against the spacer.1725.Stand the counter shaft pinion assembly (27) with its bearing cones (74) and (76) up in the reducer.26.Assemblethechangegear(29)ontothelowspeedpinion shaft.Thepartnumberstampedonthefaceofthegear should be facing you. For ease of installation, heat the gear to 300F. You may have to lean the counter shaft pinion out of the way until the change gear teeth have cleared the pinion bearing.27.Securethechangegear(29)tothelowspeedpinion(30) using the low speed pinion change gear washer (40) and the low speed pinion ESNA nut (41). Tighten the ESNA nut to the torque value given in Table 14.28.Install the bearing carrier (5) in the housing using the bearing carrierbolts(53)andwashers(54).Thebearingcarrieris dowelled in place to assure proper shaft alignment. Straight dowelpins(84)areusedinreducersizes1through6and tapered dowel pins are used in sizes 7 through 12. Follow the procedure outlined under the output cover in step 7. Tighten the bolts (53) to the torque value given in Table 12.29.Install the counter shaft triple bearing-B cup (75) and set the bearing end play on the counter shaft pinion (27). Place the proper number of shims (14) between the counter shaft pinion bearing retainer (11) and the bearing carrier (5) to achieve the end play setting specifed in Table 10. Rotate the pinion while pushingandpullingonittoseattherollersofthetapered roller bearings and therefore obtain a true end play reading. Tightenthebolts(55)withtheirwashers(56)tothetorque value specifed in Table 12.30.Install the input triple bearing-B cup (71) in its bore. Be certain that the cup is frmly seated up against its shoulder.31.Slidethecountershaftpinionspacer(9)ontothecounter shaft pinion (27). The end of the spacer with the large chamfer ontheoutsidediametermustgoupagainstthebearing. Insert the hardened counter shaft change gear key (34) in its keyway and up against the spacer.32.Standtheinputshaftpinionassembly(23)withitsbearing cones (70) and (72) up in the reducer.33.Assemblethehighspeedgear(28)ontothecountershaft pinion.Thepartnumberstampedonthefaceofthegear should be facing you. For ease of installation, heat the gear to 300F. You may have to lean the input shaft pinion assembly out of the way until the high speed gear teeth have cleared the pinion shoulder.34.Secure the high speed gear (28) to the counter shaft pinion (27) using the counter shaft change gear washer (38) and the countershaftESNAnut(39).TightentheESNAnuttothe torque value given in Table 14.35.Apply a 1/8 diameter bead of RTV732 silicone sealer to the input end of the housing. The bead should be continuous and should be to the inside of all bolt and dowel pin holes.36.Install the input cover (4) on the housing. The cover is doweled to the housing to assure precise shaft and bearing alignment. For reducer sizes 1 through 6, the cover should be ftted over the straight dowel pins (82) which will be tightly ftted into the housing. Reducer sizes 7 through 12 use two tapered dowel pins. On reducer sizes 7 through 12 insert the dowel pins into their holes and tap them gently to align the dowel pin holes. Installthebolts(49)andwashers(50).Slightlytightenone bolt near each dowel pin and again tap each dowel pin into place to create the fnal alignment. Tighten the output cover bolts (49) to the torque value found in Table 12.37.Place the input bearing-A cup (65 or 69) into the input cover.38.Usingtheinputsealcarriershims(13)andtheinputseal carrier (7), shim the input shaft assembly to the end play value specifed in Table 10 adding or deleting shims as necessary. The input shaft should be rotated back and forth while pulling andpushingontheshafttoassurethattherollersarefully seated in the cups and cones and a true end play reading is taken.39.Remove the seal carrier (7). Coat the outside diameter of the input seal (42) with a sealant and press it into the seal carrier withthespringloadedliptowardtheinsideofthereducer. Grease the seal lips.40.Cover the input shaft keyway with plastic electrical tape and lightly grease the shaft and the tape.41.Place the shims from step 38 over the lip of the seal carrier andaligntheboltholes.Applya1/8diameterbeadof RTV732 around the lip of the seal carrier and up against the shims.42.Slide the seal carrier with the shims and seal over the input shaft taking care to avoid cutting the seal on the input shaft keyway.Installthebolts(45)andwashers(46)andtighten theinputsealcarrierboltstothetorquevaluespecifedin Table 12.43.Install the oil plugs (85) and the breather (81).44.Checkthereducertoseethatallboltshavebeenproperly tightened and that all shafts rotate freely.45.Service the reducer with the proper lubrication and quantity.1825 2468 6764 63313631752 5148 4716433732662 61301278 7760 59858380 7915 858 57104041 2982853566 65422333746 451350 49431Figure 15 - Double Reduction Reducer2.25:1 to 25.63:1 RatiosMAXUM DCR 472 718154 53584274 7364 63313631752 511648 47433732662 61301278 7760 59858380 7915858 5710293540411411AAB828556 55289273839 3476 7570 6942 3433746 451350 49Figure 16 - Triple Reduction Reducer31.39:1 to 194.6:1 RatiosMAXUM TCR 19DETAIL A DETAIL B3439382792811 1456 5515858 571080 7929354041Figure 17 - Triple Reduction Reducer31.39:1 to 194.6:1 RatiosTable 15 - Parts Identication for MAXUM ReducersREF NO. DESCRIPTIONREF NO.DESCRIPTIONREF NO.DESCRIPTION 1HOUSING33INPUT SHAFT KEY61OUTPUT BRG-A CUP 2HOUSING34C/S CHANGE GEAR KEY62OUTPUT BRG-A CONE 3OUTPUT COVER35LS PINION CHANGE GEAR KEY63OUTPUT BRG-B CUP 4INPUT COVER36LS GEAR KEY64OUTPUT BRG-B CONE 5BEARING CARRIER37OUTPUT SHAFT KEY65INPUT DOUBLE BRG-A CUP 6OUTPUT SEAL CARRIER38C/S CHANGE GEAR WASHER66INPUT DOUBLE BRG-A CONE 7INPUT SEAL CARRIER39C/S ESNA NUT67INPUT DOUBLE BRG-B CUP 8LS PINION BEARING RETAINER40LS PINION CHANGE GEAR WASHER68INPUT DOUBLE BRG-B CONE 9C/S PINION SPACER41LS PINION ESNA NUT69INPUT TRIPLE BRG-A CUP 10LS PINION SPACER42INPUT SEAL70INPUT TRIPLE BRG-A CONE 11C/S PINION BEARING RETAINER43OUTPUT SEAL71INPUT TRIPLE BRG-B CUP 12LS PINION COVER45INPUT SEAL CARRIER BOLTS72INPUT TRIPLE BRG-B CONE 13INPUT SEAL CARRIER SHIM PACK46INPUT SEAL CARRIER WASHERS73C/S TRIPLE BRG-A CUP 14C/S PINION RETAINER SHIM PACK47OUTPUT SEAL CARRIER BOLTS74C/S TRIPLE BRG-A CONE 15LS PINION RETAINER SHIM PACK48OUTPUT SEAL CARRIER WASHERS75C/S TRIPLE BRG-B CUP 16OUTPUT SEAL CARRIER SHIM PACK49INPUT COVER BOLTS76C/S TRIPLE BRG-B CONE 17LS GEAR SPACER50INPUT COVER WASHERS77LS PINION BRG-A CUP 23INPUT SHAFT (SEE NOTE)51OUTPUT COVER BOLTS78LS PINION BRG-A CONE 23INPUT PINION (SEE NOTE)52OUTPUT COVER WASHERS79LS PINION BRG-B CUP 24INPUT SHELL PINION53BEARING CARRIER BOLTS80LS PINION BRG-B CONE 25SHELL PINION KEY54BEARING CARRIER WASHERS81BREATHER 27C/S PINION55C/S BEARING RETAINER BOLTS82INPUT COVER DOWEL PINS 28HIGH SPEED GEAR56C/S BEARING RETAINER WASHERS83OUTPUT COVER DOWEL PINS 29CHANGE GEAR57LS PINION RETAINER BOLTS84BEARING CARRIER DOWEL PINS 30LOW SPEED PINION58LS PINION RETAINER WASHERS85DRAIN PLUGS 31LOW SPEED GEAR59LS PINION COVER BOLTS85MAGNETIC DRAIN PLUG 32OUTPUT SHAFT60LS PINION COVER WASHERS86LIFTING LUGS NOTE: For reducers sizes 7 through 12 equipped with an external backstop refer to Table 36 for item 23.20Table 16 - Renewal Parts MAXUM Reducer Size 1REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 1 & 2ALL299608HOUSING 3ALL299606OUTPUT COVER 4ALL299604INPUT COVER 531.39 TO 194.6299610BEARING CARRIER 6ALL299614OUTPUT SEAL CARRIER 7ALL299913INPUT SEAL CARRIER 8ALL300218LS PINION BEARING RETAINER 931.39 TO 194.6299617C/S PINION SPACER 10ALL299618LS PINION SPACER 1131.39 TO 194.6299916C/S PINION BEARING RETAINER 12NOT USED ON SIZE 1 13ALL389618INPUT SEAL CARRIER SHIM PACK 1431.39 to 194.6389619C/S PINION RETAINER SHIM PACK 15ALL389620LS PINION RETAINER SHIM PACK 16ALL389617OUTPUT SEAL CARRIER SHIM PACK 17NOT USED ON SIZE 1 232.250 to 11.39299636DOUBLE INPUT SHAFT, REQUIRES PINION 24 & KEY 25 2313.95299637DOUBLE INPUT PINION 2317.09299638DOUBLE INPUT PINION 2320.93299639DOUBLE INPUT PINION 2325.63299640DOUBLE INPUT PINION 2331.39 to 70.62299647TRIPLE INPUT PINION 2386.50 to 194.6299649TRIPLE INPUT PINION 242.250, 4.134299641INPUT SHELL PINION 242.756, 5.063299642INPUT SHELL PINION 243.375, 6.200299643INPUT SHELL PINION 247.594299644INPUT SHELL PINION 249.300299645INPUT SHELL PINION 2411.39299646INPUT SHELL PINION 252.250 to 11.39299990SHELL PINION KEY 2731.39, 86.50299651C/S PINION 2738.44, 105.9299652C/S PINION 2747.08, 129.7299653C/S PINION 2757.67, 158.9299654C/S PINION 2770.62, 194.6299655C/S PINION 2831.39 to 70.62299656HIGH SPEED GEAR 2886.50 to 194.6299657HIGH SPEED GEAR 292.250, 4.134299658CHANGE GEAR 292.756, 5.063299659CHANGE GEAR 293.375, 6.200299660CHANGE GEAR 297.594299661CHANGE GEAR 299.300299662CHANGE GEAR 2911.39, 31.39, 86.50299663CHANGE GEAR 2913.95, 38.44, 105.9299664CHANGE GEAR 2917.09, 47.08, 129.7299665CHANGE GEAR 2920.93, 57.67, 158.9299666CHANGE GEAR 2925.63, 70.62, 194.6299667CHANGE GEAR 302.250 to 3.375299668LOW SPEED PINION 304.134 to 194.6299669LOW SPEED PINION 312.250 to 3.375 299670 LOW SPEED GEAR 314.134 to 194.6 299671 LOW SPEED GEAR 32ALL 299672 OUTPUT SHAFT 33ALL299986INPUT SHAFT KEY 3431.39 to 194.6299688C/S CHANGE GEAR KEY 35ALL299689LS PINION CHANGE GEAR KEY 36ALL 299690 LS GEAR KEY 37ALL299691OUTPUT SHAFT KEY 3831.39 to 194.6304951C/S CHANGE GEAR WASHER 3931.39 to 194.6304956C/S ESNA NUT 40ALL304952LS PINION CHANGE GEAR WASHER 41ALL304957LS PINION ESNA NUT 42ALL304924INPUT SEAL 43ALL304925OUTPUT SEAL 45ALL304519INPUT SEAL CARRIER BOLTS 46ALL304602INPUT SEAL CARRIER WASHERS 21Table 16 - Renewal Parts MAXUM Reducer Size 1REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 47ALL304530OUTPUT SEAL CARRIER BOLTS 48ALL304603OUTPUT SEAL CARRIER WASHERS 49ALL304535INPUT COVER BOLTS 50ALL304603INPUT COVER WASHERS 51ALL304535OUTPUT COVER BOLTS 52ALL304603OUTPUT COVER WASHERS 5331.39 to 194.6304536BEARING CARRIER BOLTS 5431.39 to 194.6304603BEARING CARRIER WASHERS 5531.39 to 194.6304518C/S BEARING RETAINER BOLTS 5631.39 to 194.6304602C/S BEARING RETAINER WASHERS 57ALL304518LS PINION RETAINER BOLTS 58ALL304602LS PINION RETAINER WASHERS 59NOT USED ON SIZE 1 60NOT USED ON SIZE 1 61-62ALL392201OUTPUT BRG-A 304808/304709 63-64ALL392202OUTPUT BRG-B 304805/304705 65-662.250 to 25.63392203INPUT DOUBLE BRG-A 403139/304741 67-682.250 to 25.63392204INPUT DOUBLE BRG-B 304847/402108 69-7031.39 to 194.6392203INPUT TRIPLE BRG-A 403139/304741 71-7231.39 to 194.6392205INPUT TRIPLE BRG-B 304833/304740 73-7431.39 to 194.6392204C/S TRIPLE BRG-A 304847/402108 75-7631.39 to 194.6392206C/S TRIPLE BRG-B 403063/402108 77-78ALL392207LS PINION BRG-A 403094/304707 79-80ALL392208LS PINION BRG-B 403094/304753 81ALL241237BREATHER 82ALL304623INPUT COVER DOWEL PINS 83ALL304623OUTPUT COVER DOWEL PINS 8431.39 to 194.6304624BEARING CARRIER DOWEL PINS 85ALL430031DRAIN PLUGS 85ALL304961MAGNETIC DRAIN PLUG NOTE: When replacing bearings that have been in service, both the cup and the cone should be replaced.Recommended spare parts for MAXUM reducer size 1:Level 1 Spare parts consist of reference numbers 13-16, 42, 43, and 61-80.Level 2 Spare parts consist of reference numbers 23-32 plus Level 1 recommended spare parts. The low speed gear (31), the output shaft (32), and LS Gear Key (36) may be ordered as an assembly by ordering part number 389638 for reducers with total ratios from 2.250 through 3.375 or part number 389639 for reducers with total ratios from 4.134 through 194.6.

22Table 17 - Renewal Parts MAXUM Reducer Size 2REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 1 & 2ALL299909HOUSING 3ALL299907OUTPUT COVER 4ALL299905INPUT COVER 531.39 to 194.6299911BEARING CARRIER 6ALL301117OUTPUT SEAL CARRIER 7ALL299913INPUT SEAL CARRIER 8ALL300518LS PINION BEARING RETAINER 931.39 to 194.6299918C/S PINION SPACER 10ALL299919LS PINION SPACER 1131.39 to 194.6299916C/S PINION BEARING RETAINER 12NOT USED ON SIZE 2 13ALL389618INPUT SEAL CARRIER SHIM PACK 1431.39 to 194.6389619C/S PINION RETAINER SHIM PACK 15ALL389623LS PINION RETAINER SHIM PACK 16ALL389627OUTPUT SEAL CARRIER SHIM PACK 17NOT USED ON SIZE 2 232.250 to 9.300299937DOUBLE INPUT SHAFT, REQUIRES PINION 24 & KEY 25 2311.39299938DOUBLE INPUT PINION 2313.95299939DOUBLE INPUT PINION 2317.09299940DOUBLE INPUT PINION 2320.93299941DOUBLE INPUT PINION 2325.63299942DOUBLE INPUT PINION 2331.39 to 70.62299948TRIPLE INPUT PINION 2386.50 to 194.6299950TRIPLE INPUT PINION 242.250 to 4.134299943INPUT SHELL PINION 242.756 to 5.063299944INPUT SHELL PINION 243.375 to 6.200299945INPUT SHELL PINION 247.594299946INPUT SHELL PINION 249.300299947INPUT SHELL PINION 252.250 to 9.300300591SHELL PINION KEY 2731.39, 86.50299952C/S PINION 2738.44, 105.9299953C/S PINION 2747.08, 129.7299954C/S PINION 2757.67, 158.9299955C/S PINION 2770.62, 194.6299956C/S PINION 2831.39 to 70.62299957HIGH SPEED GEAR 2886.50 to 194.6299958HIGH SPEED GEAR 292.250 to 4.134299959CHANGE GEAR 292.756 to 5.063299960CHANGE GEAR 293.375 to 6.200299961CHANGE GEAR 297.594299962CHANGE GEAR 299.300299963CHANGE GEAR 2911.39, 31.39, 86.50299964CHANGE GEAR 2913.95, 38.44, 105.9299965CHANGE GEAR 2917.09, 47.08, 129.7299966CHANGE GEAR 2920.93, 57.67, 158.9299967CHANGE GEAR 2925.63, 70.62, 194.6299968CHANGE GEAR 302.250 to 3.375299969LOW SPEED PINION 304.134 to 194.6299970LOW SPEED PINION 312.250 to 3.375 299971 LOW SPEED GEAR 314.134 to 194.6 299972 LOW SPEED GEAR 32ALL 299973 OUTPUT SHAFT 33ALL299986INPUT SHAFT KEY 3431.39 to 194.6299990C/S CHANGE GEAR KEY 35ALL300591LS PINION CHANGE GEAR KEY 36ALL 299992 LS GEAR KEY 37ALL301190OUTPUT SHAFT KEY 3831.39 to 194.6304951C/S CHANGE GEAR WASHER 3931.39 to 194.6304956C/S ESNA NUT 40ALL304952LS PINION CHANGE GEAR WASHER 41ALL304957LS PINION ESNA NUT 42ALL304924INPUT SEAL 43ALL351113OUTPUT SEAL 45ALL304519INPUT SEAL CARRIER BOLTS 46ALL304602INPUT SEAL CARRIER WASHERS 47ALL304529OUTPUT SEAL CARRIER BOLTS 23Table 17 - Renewal Parts MAXUM Reducer Size 2REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 48ALL304603OUTPUT SEAL CARRIER WASHERS 49ALL304535INPUT COVER BOLTS 50ALL304603INPUT COVER WASHERS 51ALL304535OUTPUT COVER BOLTS 52ALL304603OUTPUT COVER WASHERS 5331.39 TO 194.6304536BEARING CARRIER BOLTS 5431.39 TO 194.6304603BEARING CARRIER WASHERS 5531.39 TO 194.6304519C/S BEARING RETAINER BOLTS 5631.39 TO 194.6304602C/S BEARING RETAINER WASHERS 57ALL304519LS PINION RETAINER BOLTS 58ALL304602LS PINION RETAINER WASHERS 59NOT USED ON SIZE 2 60NOT USED ON SIZE 2 61ALL392209OUTPUT BRG-A 304813/304715 63ALL392210OUTPUT BRG-B 304812/304713 652.250 TO 25.63392203INPUT DOUBLE BRG-A 403139/304741 672.250 TO 25.63392204INPUT DOUBLE BRG-B 304847/402108 6931.39 TO 194.6392203INPUT TRIPLE BRG-A 403139/304741 7131.39 TO 194.6392205INPUT TRIPLE BRG-B 304833/304740 7331.39 TO 194.6392204C/S TRIPLE BRG-A 304847/402108 7531.39 TO 194.6392211C/S TRIPLE BRG-B 304836/304743 77ALL392212LS PINION BRG-A 304839/304747 79ALL392202LS PINION BRG-B 304805/304705 81ALL241237BREATHER 82ALL304623INPUT COVER DOWEL PINS 83ALL304623OUTPUT COVER DOWEL PINS 8431.39 TO 194.6304624BEARING CARRIER DOWEL PINS 85ALL430031DRAIN PLUGS 85ALL304961MAGNETIC DRAIN PLUG NOTE: When replacing bearings that have been in service, both the cup and the cone should be replaced.Recommended spare parts for MAXUM reducer size 2Level 1 Spare parts consist of reference numbers 13-16, 42, 43, and 61-80.Level 2 Spare parts consist of reference numbers 23-32 plus Level 1 recommended spare parts. The low speed gear (31), the output shaft (32), and LS Gear Key (36) may be ordered as an assembly by ordering part number 389640 for reducers with total ratios from 2.250 through 3.375 or part number 389641 for reducers with total ratios from 4.134 through 194.624Table 18 - Renewal Parts MAXUM Reducer Size 3REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 1 & 2ALL300211HOUSING 3ALL300209OUTPUT COVER 4ALL300207INPUT COVER 531.39 to 194.6300213BEARING CARRIER 6ALL300217OUTPUT SEAL CARRIER 7ALL300515INPUT SEAL CARRIER 8ALL300219LS PINION BEARING RETAINER 931.39 to 194.6300220C/S PINION SPACER 10ALL300221LS PINION SPACER 1131.39 to 194.6300218C/S PINION BEARING RETAINER 12NOT USED IN SIZE 3 13ALL389622INPUT SEAL CARRIER SHIM PACK 1431.39 to 194.6389620C/S PINION RETAINER SHIM PACK 15ALL389622LS PINION RETAINER SHIM PACK 16ALL389621OUTPUT SEAL CARRIER SHIM PACK 17NOT USED IN SIZE 3 232.250 to 11.39300239DOUBLE INPUT SHAFT, REQUIRES PINION 24 & KEY 25 2313.95300240DOUBLE INPUT PINION 2317.09300241DOUBLE INPUT PINION 2320.93300242DOUBLE INPUT PINION 2325.63300243DOUBLE INPUT PINION 2331.39 to 70.62300250TRIPLE INPUT PINION 2386.50 to 194.6300252TRIPLE INPUT PINION 242.250, 4.134300244INPUT SHELL PINION 242.756, 5.063300245INPUT SHELL PINION 243.375, 6.200300246INPUT SHELL PINION 247.594300247INPUT SHELL PINION 249.300300248INPUT SHELL PINION 2411.39300249INPUT SHELL PINION 252.250 to 11.39300591SHELL PINION KEY 2731.39, 86.50300254C/S PINION 2738.44, 105.9300255C/S PINION 2747.08, 129.7300256C/S PINION 2757.67, 158.9300257C/S PINION 2770.62, 194.6300258C/S PINION 2831.39 to 70.62300259HIGH SPEED GEAR 2886.50 to 194.6300260HIGH SPEED GEAR 292.250, 4.134300261CHANGE GEAR 292.756, 5.063300262CHANGE GEAR 293.375, 6.200300263CHANGE GEAR 297.594300264CHANGE GEAR 299.300300265CHANGE GEAR 2911.39, 31.39, 86.50300266CHANGE GEAR 2913.95, 38.44, 105.9300267CHANGE GEAR 2917.09, 47.08, 129.7300268CHANGE GEAR 2920.93, 57.67, 158.9300269CHANGE GEAR 2925.63, 70.62, 194.6300270CHANGE GEAR 302.250 to 3.375300271LOW SPEED PINION 304.134 to 194.6300272LOW SPEED PINION 312.250 to 3.375 300273 LOW SPEED GEAR 314.134 to 194.6 300274 LOW SPEED GEAR 32ALL 300275 OUTPUT SHAFT 33ALL443090INPUT SHAFT KEY 3431.39 to 194.6300291C/S CHANGE GEAR KEY 35ALL300292LS PINION CHANGE GEAR KEY 36ALL 300293 LS GEAR KEY 37ALL300294OUTPUT SHAFT KEY 3831.39 to 194.6304952C/S CHANGE GEAR WASHER 3931.39 to 194.6304957C/S ESNA NUT 40ALL304952LS PINION CHANGE GEAR WASHER 41ALL304957LS PINION ESNA NUT 42ALL304932INPUT SEAL 43ALL304933OUTPUT SEAL 45ALL304519INPUT SEAL CARRIER BOLTS 46ALL304602INPUT SEAL CARRIER WASHERS 47ALL304529OUTPUT SEAL CARRIER BOLTS 25Table 18 - Renewal Parts MAXUM Reducer Size 3REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 48ALL304603OUTPUT SEAL CARRIER WASHERS 49ALL304545INPUT COVER BOLTS 50ALL304604INPUT COVER WASHERS 51ALL304546OUTPUT COVER BOLTS 52ALL304604OUTPUT COVER WASHERS 5331.39 to 194.6304548BEARING CARRIER BOLTS 5431.39 to 194.6304604BEARING CARRIER WASHERS 5531.39 to 194.6304518C/S BEARING RETAINER BOLTS 5631.39 to 194.6304602C/S BEARING RETAINER WASHERS 57ALL304519LS PINION RETAINER BOLTS 58ALL304602LS PINION RETAINER WASHERS 59NOT USED IN SIZE 3 60NOT USED IN SIZE 3 61ALL392213OUTPUT BRG-A 403106/402150 63ALL392214OUTPUT BRG-B 403005/304717 652.250 to 25.63392215INPUT DOUBLE BRG-A 304835/304742 672.250 to 25.63392216INPUT DOUBLE BRG-B 304848/304707 6931.39 to 194.6392215INPUT TRIPLE BRG-A 304835/304742 7131.39 to 194.6392205INPUT TRIPLE BRG-B 304833/304740 7331.39 to 194.6392216C/S TRIPLE BRG-A 304848/304707 7531.39 to 194.6392208C/S TRIPLE BRG-B 403094/304753 77ALL392202LS PINION BRG-A 304805/304705 79ALL392217LS PINION BRG-B 304809/304710 81ALL241237BREATHER 82ALL304624INPUT COVER DOWEL PINS 83ALL304624OUTPUT COVER DOWEL PINS 8431.39 to 194.6304624BEARING CARRIER DOWEL PINS 85ALL430031DRAIN PLUGS 85ALL304961MAGNETIC DRAIN PLUG NOTE: When replacing bearings that have been in service, both the cup and the cone should be replaced.Recommended spare parts for MAXUM reducer size 3:Level 1 Spare parts consist of reference numbers 13-16, 42, 43, and 61-80.Level 2 Spare parts consist of reference numbers 23-32 plus Level 1 recommended spare parts.

The low speed gear (31), the output shaft (32), and LS Gear Key (36) may be ordered as an assembly by ordering part number 389642 for reducers with total ratios from 2.250 through 3.375 or part number 389643 for reducers with total ratios from 4.134 through 194.6

26Table 19 - Renewal Parts MAXUM Reducer Size 4REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 1 & 2ALL300511HOUSING 3ALL300509OUTPUT COVER 4ALL300507INPUT COVER 531.39 to 194.6300513BEARING CARRIER 6ALL300517OUTPUT SEAL CARRIER 7ALL300515INPUT SEAL CARRIER 8ALL301120LS PINION BEARING RETAINER 931.39 to 194.6300520C/S PINION SPACER 10ALL300521LS PINION SPACER 1131.39 to 194.6300518C/S PINION BEARING RETAINER 12NOT USED ON SIZE 4 13ALL389622INPUT SEAL CARRIER SHIM PACK 1431.39 to 194.6389623C/S PINION RETAINER SHIM PACK 15ALL389628LS PINION RETAINER SHIM PACK 16ALL389606OUTPUT SEAL CARRIER SHIM PACK 17NOT USED ON SIZE 4 232.250 to 9.300300539DOUBLE INPUT SHAFT, REQUIRES PINION 24 & KEY 25 2311.39300540DOUBLE INPUT PINION 2313.95300541DOUBLE INPUT PINION 2317.09300542DOUBLE INPUT PINION 2320.93300543DOUBLE INPUT PINION 2325.63300544DOUBLE INPUT PINION 2331.39 to 70.62300550TRIPLE INPUT PINION 2386.50 to 194.6300552TRIPLE INPUT PINION 242.250, 4.134300545INPUT SHELL PINION 242.756, 5.063300546INPUT SHELL PINION 243.375, 6.200300547INPUT SHELL PINION 247.594300548INPUT SHELL PINION 249.300300549INPUT SHELL PINION 252.250 to 9.300300591SHELL PINION KEY 2731.39, 86.50300554C/S PINION 2738.44, 105.9300555C/S PINION 2747.08, 129.7300556C/S PINION 2757.67, 158.9300557C/S PINION 2770.62, 194.6300558C/S PINION 2831.39 to 70.62300559HIGH SPEED GEAR 2886.50 to 194.6300560HIGH SPEED GEAR 292.250, 4.134300561CHANGE GEAR 292.756, 5.063300562CHANGE GEAR 293.375, 6.200300563CHANGE GEAR 297.594300564CHANGE GEAR 299.300300565CHANGE GEAR 2911.39, 31.39, 86.50300566CHANGE GEAR 2913.95, 38.44, 105.9300567CHANGE GEAR 2917.08, 47.08, 129.7300568CHANGE GEAR 2920.93, 57.67, 158.9300569CHANGE GEAR 2925.63, 70.62, 194.6300570CHANGE GEAR 302.250 to 3.375300571LOW SPEED PINION 304.134 to 194.6300572LOW SPEED PINION 312.250 to 3.375 300573 LOW SPEED GEAR 314.134 to 194.6 300574 LOW SPEED GEAR 32ALL 300575 OUTPUT SHAFT 33ALL443090INPUT SHAFT KEY 3431.39 to 194.6300591C/S CHANGE GEAR KEY 35ALL301193LS PINION CHANGE GEAR KEY 36ALL 300593 LS GEAR KEY 37ALL300594OUTPUT SHAFT KEY 3831.39 to 194.6304952C/S CHANGE GEAR WASHER 3931.39 to 194.6304957C/S ESNA NUT 40ALL304952LS PINION CHANGE GEAR WASHER 41ALL304957LS PINION ESNA NUT 42ALL304932INPUT SEAL 43ALL304937OUTPUT SEAL 45ALL304519INPUT SEAL CARRIER BOLTS 46ALL304602INPUT SEAL CARRIER WASHERS 47ALL304530OUTPUT SEAL CARRIER BOLTS 27Table 19 - Renewal Parts MAXUM Reducer Size 4REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 48ALL304603OUTPUT SEAL CARRIER WASHERS 49ALL304545INPUT COVER BOLTS 50ALL304604INPUT COVER WASHERS 51ALL304546OUTPUT COVER BOLTS 52ALL304604OUTPUT COVER WASHERS 5331.39 to 194.6304548BEARING CARRIER BOLTS 5431.39 to 194.6304604BEARING CARRIER WASHERS 5531.39 to 194.6304519C/S BEARING RETAINER BOLTS 5631.39 to194.6304602C/S BEARING RETAINER WASHERS 57ALL304519LS PINION RETAINER BOLTS 58ALL304602LS PINION RETAINER WASHERS 59NOT USED ON SIZE 4 60NOT USED ON SIZE 4 61ALL392218OUTPUT BRG-A 403072/304723 63ALL392213OUTPUT BRG-B 403106/402150 652.250 to 25.63392215INPUT DOUBLE BRG-A 304835/304742 672.250 to 25.63392219INPUT DOUBLE BRG-B 304849/304747 6931.39 to 194.6392215INPUT TRIPLE BRG-A 304835/304742 7131.39 to 194.6392206INPUT TRIPLE BRG-B 403063/402108 7331.39 to 194.6392220C/S TRIPLE BRG-A 304810/304748 7531.39 to 194.6392220C/S TRIPLE BRG-B 304810/304748 77ALL392214LS PINION BRG-A 403005/304717 79ALL392214LS PINION BRG-B 403005/304717 81ALL241237BREATHER 82ALL304624INPUT COVER DOWEL PINS 83ALL304624OUTPUT COVER DOWEL PINS 8431.39 to 194.6304624BEARING CARRIER DOWEL PINS 85ALL430031DRAIN PLUGS 85ALL304961MAGNETIC DRAIN PLUG NOTE: When replacing bearings that have been in service, both the cup and the cone should be replaced. Recommended spare parts for MAXUM reducer size 4:Level 1 Spare parts consist of reference numbers 13-16, 42, 43, and 61-80.Level 2 Spare parts consist of reference numbers 23-32 plus Level 1 recommended spare parts.

The low speed gear (31), the output shaft (32), and LS Gear Key (36) may be ordered as an assembly by ordering part number 389644 for reducers with total ratios from 2.250 through 3.375 or part number 389645 for reducers with total ratios from 4.134 through 194.6.

28 Table 20 - Renewal Parts MAXUM Reducer Size 5REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 1 & 2ALL300812HOUSING 3ALL300810OUTPUT COVER 4ALL300808INPUT COVER 531.39 to 194.6300814BEARING CARRIER 6ALL300818OUTPUT SEAL CARRIER 7ALL301117INPUT SEAL CARRIER 8ALL300820LS PINION BEARING RETAINER 931.39 to 194.6300821C/S PINION SPACER 10ALL300822LS PINION SPACER 1131.39 to 194.6300819C/S PINION BEARING RETAINER 12NOT USED ON SIZE 5 13ALL389627INPUT SEAL CARRIER SHIM PACK 1431.39 to 194.6389624C/S PINION RETAINER SHIM PACK 15ALL389625LS PINION RETAINER SHIM PACK 16ALL389626OUTPUT SEAL CARRIER SHIM PACK 17NOT USED ON SIZE 5 232.250 to 9.300300840DOUBLE INPUT SHAFT, REQUIRES PINION 24 & KEY 25 2311.39300841DOUBLE INPUT PINION 2313.95300842DOUBLE INPUT PINION 2317.09300843DOUBLE INPUT PINION 2320.93300844DOUBLE INPUT PINION 2325.63300845DOUBLE INPUT PINION 2331.39 to 70.62300852TRIPLE INPUT PINION 2386.50 to 194.6300854TRIPLE INPUT PINION 242.250, 4.134300846INPUT SHELL PINION 242.756, 5.063300847INPUT SHELL PINION 243.375, 6.200300848INPUT SHELL PINION 247.594300849INPUT SHELL PINION 249.300300850INPUT SHELL PINION 252.250 to 9.300301491SHELL PINION KEY 2731.39, 86.50300855C/S PINION 2738.44, 105.9300856C/S PINION 2747.08, 129.7300857C/S PINION 2757.67, 158.9300858C/S PINION 2770.62, 194.6300859C/S PINION 2831.39 to 70.62300860HIGH SPEED GEAR 2886.50 to 194.6300861HIGH SPEED GEAR 292.250, 4.134300862CHANGE GEAR 292.756, 5.063300863CHANGE GEAR 293.375, 6.200300864CHANGE GEAR 297.594300865CHANGE GEAR 299.300300866CHANGE GEAR 2911.39, 31.39, 86.50300867CHANGE GEAR 2913.95, 38.44, 105.9300868CHANGE GEAR 2917.09, 47.08, 129.7300869CHANGE GEAR 2920.93, 57.67, 158.9300870CHANGE GEAR 2925.63, 70.62, 194.6300871CHANGE GEAR 302.250 to 3.375300872LOW SPEED PINION 304.134 to 194.6300873LOW SPEED PINION 312.250 to 3.375 300874 LOW SPEED GEAR 314.134 to 194.6 300875 LOW SPEED GEAR 32ALL 300876 OUTPUT SHAFT 332.250 to 25.63443279DOUBLE INPUT SHAFT KEY 3331.39 to 194.6443090TRIPLE INPUT SHAFT KEY 3431.39 to 194.6300892CIS CHANGE GEAR KEY 35ALL300893LS PINION CHANGE GEAR KEY 36ALL 300894 LS GEAR KEY 37ALL300895OUTPUT SHAFT KEY 3831.39 to 194.6304952C/S CHANGE GEAR WASHER 3931.39 to 194.6304957C/S ESNA NUT 40ALL304953LS PINION CHANGE GEAR WASHER 41ALL304958LS PINION ESNA NUT 422.250 to 25.63351113DOUBLE INPUT SEAL 4231.39 to 194.6304935TRIPLE INPUT SEAL 43ALL014636OUTPUT SEAL 45ALL304529INPUT SEAL CARRIER BOLTS 29 Table 20 - Renewal Parts MAXUM Reducer Size 5REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 46ALL304603INPUT SEAL CARRIER WASHERS 47ALL304530OUTPUT SEAL CARRIER BOLTS 48ALL304603OUTPUT SEAL CARRIER WASHERS 49ALL304546INPUT COVER BOLTS 50ALL304604INPUT COVER WASHERS 51ALL304547OUTPUT COVER BOLTS 52ALL304604OUTPUT COVER WASHERS 5331.39 to 194.6304549BEARING CARRIER BOLTS 5431.39 to 194.6304604BEARING CARRIER WASHERS 5531.39 to 194.6304520C/S BEARING RETAINER BOLTS 5631.39 to 194.6304602C/S BEARING RETAINER WASHERS 57ALL304520LS PINION RETAINER BOLTS 58ALL304602LS PINION RETAINER WASHERS 59NOT USED ON SIZE 5 60NOT USED ON SIZE 5 61ALL392221OUTPUT BRG-A 403022/402201 63ALL392222OUTPUT BRG-B 304802/402041 652.250 to 25.63392209INPUT DOUBLE BRG-A 304813/304715 672.250 to 25.63392224INPUT DOUBLE BRG-B 304844/402102 6931.39 to 194.6392225INPUT TRIPLE BRG-A 304813/304714 7131.39 to 194.6392206INPUT TRIPLE BRG-B 403063/402108 7331.39 to 194.6392220C/S TRIPLE BRG-A 304810/304748 7531.39 to 194.6392226C/S TRIPLE BRG-B 403027/304712 77ALL392227LS PINION BRG-A 304817/304719 79ALL392228LS PINION BRG-B 403130/402188 81ALL245237BREATHER 82ALL304624INPUT COVER DOWEL PINS 83ALL304624OUTPUT COVER DOWEL PINS 8431.39 to 194.6304624BEARING CARRIER DOWEL PINS 85ALL430033DRAIN PLUGS 85ALL430062MAGNETIC DRAIN PLUG NOTE: When replacing bearings that have been in service, both the cup and the cone should be replaced.Recommended spare parts for MAXUM reducer size 5:Level 1 Spare parts consist of reference numbers 13-16, 42, 43, and 61-80.Level 2 Spare parts consist of reference numbers 23-32 plus Level 1 recommended spare parts. The low speed gear (31), the output shaft (32), and LS Gear Key (36) may be ordered as an assembly by ordering part number 389646 for reducers with total ratios from 2.250 through 3.375 or part number 389647 for reducers with total ratios from 4.134 through 194.6

30Table 21 - Renewal Parts MAXUM Reducer Size 6REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 1 & 2ALL301113HOUSING 3ALL301111OUTPUT COVER 4ALL301109INPUT COVER 531.39 to 194.6301115BEARING CARRIER 6ALL301119OUTPUT SEAL CARRIER 7ALL301117INPUT SEAL CARRIER 8ALL301121LS PINION BEARING RETAINER 931.39 to 194.6301122C/S PINION SPACER 10ALL301123LS PINION SPACER 1131.39 to 194.6301120C/S PINION BEARING RETAINER 12NOT USED ON SIZE 6 13ALL389627INPUT SEAL CARRIER SHIM PACK 1431.39 to 194.6389628C/S PINION RETAINER SHIM PACK 15ALL389629LS PINION RETAINER SHIM PACK 16ALL389630OUTPUT SEAL CARRIER SHIM PACK 17NOT USED ON SIZE 6 232.250 to 9.300301141DOUBLE INPUT SHAFT, REQUIRES PINION 24 & KEY 25 2311.39301142DOUBLE INPUT PINION 2313.95301143DOUBLE INPUT PINION 2317.09301144DOUBLE INPUT PINION 2320.93301145DOUBLE INPUT PINION 2325.63301146DOUBLE INPUT PINION 2331.39 to 70.62301152TRIPLE INPUT PINION 2386.50 to 194.6301154TRIPLE INPUT PINION 242.250, 4.134301147INPUT SHELL PINION 242.756, 5.063301148INPUT SHELL PINION 243.375, 6.200301149INPUT SHELL PINION 247.594301150INPUT SHELL PINION 249.300301151INPUT SHELL PINION 252.250 to 9.300301792SHELL PINION KEY 2731.39, 86.50301156C/S PINION 2738.44, 105.9301157C/S PINION 2747.08, 129.7301158C/S PINION 2757.67, 158.9301159C/S PINION 2770.62, 194.6301160C/S PINION 2831.39 to 70.62301161HIGH SPEED GEAR 2886.50 to 194.6301162HIGH SPEED GEAR 292.250, 4.134301163CHANGE GEAR 292.756, 5.063301164CHANGE GEAR 293.375, 6.200301165CHANGE GEAR 297.594301166CHANGE GEAR 299.300301167CHANGE GEAR 2911.39, 31.39, 86.50301168CHANGE GEAR 2913.95, 38.44, 105.9301169CHANGE GEAR 2917.09, 47.08, 129.7301170CHANGE GEAR 2920.93, 57.67, 158.9301171CHANGE GEAR 2925.63, 70.62, 194.6301172CHANGE GEAR 302.250 to 3.375301173LOW SPEED PINION 304.134 to 194.6301174LOW SPEED PINION 312.250 to 3.375 301175 LOW SPEED GEAR 314.134 to 194.6 301176 LOW SPEED GEAR 32ALL 301177 OUTPUT SHAFT 332.250 to 25.63443279DOUBLE INPUT SHAFT KEY 3331.39 to 194.6443090TRIPLE INPUT SHAFT KEY 3431.39 to 194.6301193C/S CHANGE GEAR KEY 35ALL301194LS PINION CHANGE GEAR KEY 36ALL 301195 LS GEAR KEY 37ALL301196OUTPUT SHAFT KEY 3831.39 to 194.6304952C/S CHANGE GEAR WASHER 3931.39 to 194.6304957C/S ESNA NUT 40ALL304953LS PINION CHANGE GEAR WASHER 41ALL304958LS PINION ESNA NUT 422.250 to 25.63351113DOUBLE INPUT SEAL 4231.39 to 194.6304935TRIPLE INPUT SEAL 43ALL245545OUTPUT SEAL 45ALL304529INPUT SEAL CARRIER BOLTS 31Table 21 - Renewal Parts MAXUM Reducer Size 6REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 46ALL304603INPUT SEAL CARRIER WASHERS 47ALL304541OUTPUT SEAL CARRIER BOLTS 48ALL304604OUTPUT SEAL CARRIER WASHERS 49ALL304593INPUT COVER BOLTS 50ALL304604INPUT COVER WASHERS 51ALL304547OUTPUT COVER BOLTS 52ALL304604OUTPUT COVER WASHERS 5331.39 to 194.6304592BEARING CARRIER BOLTS 5431.39 to194.6304604BEARING CARRIER WASHERS 5531.39 to 194.6304519C/S BEARING RETAINER BOLTS 5631.39 to 194.6304602C/S BEARING RETAINER WASHERS 57ALL304530LS PINION RETAINER BOLTS 58ALL304603LS PINION RETAINER WASHERS 59NOT USED IN SIZE 6 60NOT USED IN SIZE 6 61ALL392229OUTPUT BRG-A 304840/304749 63ALL392222OUTPUT BRG-B 304802/402041 652.250 to 25.63392209INPUT DOUBLE BRG-A 304813/304715 672.250 to 25.63392230INPUT DOUBLE BRG-B 304846/304717 6931.39 to 194.6392225INPUT TRIPLE BRG-A 304813/304714 7131.39 to 194.6392207INPUT TRIPLE BRG-B 403094/304707 7331.39 to 194.6392214C/S TRIPLE BRG-A 403005/304717 7531.39 to 194.6392214C/S TRIPLE BRG-B 403005/304717 77ALL392227LS PINION BRG-A 403059/304719 79ALL392231LS PINION BRG-B 304841/304750 81ALL245237BREATHER 82ALL304624INPUT COVER DOWEL PINS 83ALL304624OUTPUT COVER DOWEL PINS 8431.39 to 194.6304624BEARING CARRIER DOWEL PINS 85ALL430033DRAIN PLUGS 85ALL430062MAGNETIC DRAIN PLUG NOTE: When replacing bearings that have been in service, both the cup and the cone should be replaced.Recommended spare parts for MAXUM reducer size 6:Level 1 Spare parts consist of reference numbers 13-16, 42, 43, and 61-80.Level 2 Spare parts consist of reference numbers 23-32 plus Level 1 recommended spare parts. The low speed gear (31), the output shaft (32), and LS Gear Key (36) may be ordered as an assembly by ordering part number 389648 for reducers with total ratios from 2.250 through 3.375 or part number 389649 for reducers with total ratios from 4.134 through 194.6.

32Table 22 - Renewal Parts MAXUM Reducer Size 7REF NO.APPLICABLE RATIOSPART NUMBERDESCRIPTION 15.063 to 25.63299262HOUSING 231.39 to 194.6299262HOUSING 3ALL299261OUTPUT COVER 4ALL299260INPUT COVER 531.39 to 194.6299263BEARING CARRIER 6ALL301420OUTPUT SEAL CARRIER 7ALL301418INPUT SEAL CARRIER 8ALL301422LS PINION BEARING RETAINER 931.39 to 194.6301423C/S PINION SPACER 10ALL301424LS PINION SPACER 1131.39 to 194.6301722C/S PINION BEARING RETAINER 12ALL301425LS PINION COVER 13ALL389631INPUT SEAL CARRIER SHIM PACK 1431.39 to 194.6389635C/S PINION RETAINER SHIM PACK 15ALL389632LS PINION RETAINER SHIM PACK 16ALL389633OUTPUT SEAL CARRIER SHIM PACK 17ALL301501LS GEAR SPACER 235.063 to 9.300 (SEE NOTE)301442DOUBLE INPUT SHAFT, REQUIRES PINION 24 & KEY 25 2311.39 (SEE NOTE)301447DOUBLE INPUT PINION 2313.95 (SEE NOTE)301446DOUBLE INPUT PINION 2317.09 (SEE NOTE)301445DOUBLE INPUT PINION 2320.93 (SEE NOTE)301444DOUBLE INPUT PINION 2325.63 (SEE NOTE)301443DOUBLE INPUT PINION 2331.39 to 70.62 (SEE NOTE)301455TRIPLE INPUT PINION 2386.50 to 129.7 (SEE NOTE)301454TRIPLE INPUT PINION 23158.9 to 194.6 (SEE NOTE)301453TRIPLE INPUT PINION 245.063301451INPUT SHELL PINION 246.200301450INPUT SHELL PINION 247.594301449INPUT SHELL PINION 249.300301448INPUT SHELL PINION 255.063 to 9.300301792SHELL PINION KEY 2731.39301460C/S PINION 2738.44301459C/S PINION 2747.08, 86.50301458C/S PINION 2757.67, 105.9, 158.9301457C/S PINION 2770.62,129.7, 194.6301456C/S PINION 2831.39 to 70.62301461HIGH SPEED GEAR 2886.50 to 129.7301502HIGH SPEED GEAR 28158.9 to 194.6301462HIGH SPEED GEAR 295.063301463CHANGE GEAR 296.200301464CHANGE GEAR 297.594301465CHANGE GEAR 299.300301466CHANGE GEAR 2911.39, 31.39301467CHANGE