Large Horsepower Dodge Reducer

Bronze Award
 MagnaGearXTR
Product Scope
Torque
Rating
(In-Lbs)

920K

700K
Planetary gearing
525K

390K

285K Helical gearing • Universal Housing

210K • Same housing for Right Angle and Parallel

• Same housing for Right-hand or Left-hand
140K Over laps with Torque Arm

100K
55 – 1,500 Kw ….. in 8 sizes
Overview
• A new large horsepower gear reducer developed for
applications in the bulk materials handling industries.
• The product provides high quality reducers for
applications with motor horsepower from 75 Hp to
over 2,000 HP (55 Kw to over 1,500 Kw) with a 1.5
service factor
• Sizes up to 390,000 in-lbs (44,000 N-m) torque will be
helical or bevel helical
• Sizes from 525,000 in-lbs (60,000 N-m) torque will be
based on planetary gear technology proven in the
Dodge CST
• Speed adjustment may be achieved with VFD
• Mechanical soft start can be provided via a shaft or
base mounted fluid coupling
 MagnaGearXTR
Dodge Reliability in a New Package
• Utilizes Proven Dodge Gear Engineering and Manufacturing
Expertise
– CST technology for Planetary Gearing
• 1970’s Introduced first CSTs
• 1981 Introduced wet clutch technology
• Over 2,000 CSTs up to 2,500 HP
(1,900 Kw) sold
– Top 3 Coal Mines in US
– Top 7 Coal Mines in China
– Top 6 Coal Mines in Australia

– Torque Arm technology for Helical Gearing

• 1949 Introduced first Torque Arm reducer
• 1972 Introduced TXT
• 2000 Introduced TA II
• Market leader
525 K : Cutaway View
100K Thru 390K Design

• All helical / bevel helical

• Monobloc housing
• Foot mounted
• Shaft mounted
– Hollow w/ twin tapered bushings
– Solid shaft
• Flipable design
MagnaGear Differentiators
• 5000 hr bearing L10 life vs. Falk < 2500 hrs
• Tandem seals standard with HNBR vs. Nitrile or Viton
• Housing design for enhanced thermal dispersion
Reliability • Twin taper bushing minimizes reducer wobble
• Standard oil sampling port & 3 axis vibration monitoring provisions
• Superior backstop design

• Longer bearing life / better seals / improved cooling = Lower TCO

• All Baldor/Dodge/Reliance package
Cost • One warranty
• One part number

• Twin Taper bushing systems for ease of removal

• Oversized inspection covers from better accessibility
Ease of repair • Bolted end covers instead of bore plugs

• Planetary sizes (525K, 700K and 920K) significantly smaller

Power density than competitive units

Bronze
Award
Housings
• Large access plate for monoblock
maintenance
• Modular design - same housing for right
angle and parallel
• Metric dimensions for global compatibility
• Flipable design for right hand or left hand
applications – reduce spares
Configurations
• Right Angle
– Triple Reduction
– 15 Ratios Right angle
– 12.5:1 to 63.0:1

• Parallel
– Double Reduction – all sizes
• 13 Ratios
• 8.0:1 to 28:1
– Triple Reduction (100 – 390K)
• 7 Ratios Offset parallel
• 31.5:1 to 63:1
 Typical Installation Configurations

700K Offset parallel - base mounted

525K Rt angle swingbase w/ fluid coupling

Bearings

• Exceed AGMA Standards

• Greater than 5000 hrs L-10 unadjusted vs
competition < 2500 hours L-10

• Example unadjusted L-10 @ typical service

factors
– >19,000 hrs L-10 at 1.5 SF
– >28,000 hrs L-10 at 1.7 SF
– >49,000 hrs L-10 at 2.0 SF
Seals

• Tandem seal design - excludes

contaminates
• HBNR vs Nitrile or Viton –longer
life
• Radial lip with grease cavity
• Taconite style as option
 MagnaGear XTR Nomenclature

Type Size Configuration Output Shaft Stages Ratio

C – CST 100 H – Horizontal R – Right Angle S - Solid L – Left Hand 2 8.0

G – MagnaGear 140 V – Vertical P – Parallel H – Hollow R – Right Hand 3
210
285
390
525
700
920 63.0

Example:
G 525 H R S L 3 – 25.0

Size 525K, Horizontal, Right Angle, Solid Shaft, Left Hand Output, 3 Stage, 25.0:1 Ratio
MagnaGear Lineup

100 150 200 285 390 525 700 920

525 Competitive Comparison
Size 525 Magnagear
Max Torque rating 525,000 in-lbs (60,000 N-m)
Unit weight 3570 lbs (1623Kg)
Falk Drive One M1190DBC3
Max Torque Rating 530,000 in-lbs
(60,000 N-m)
Unit weight 3968 lbs (1804Kg)
Falk A-Plus 445AB3
Max Torque Rating 530,000 in-lbs (60,000 N-
m)
Unit weight 4380 lbs (1991Kg)
Design Benefit - Modularity
MagnaGear XTR 700 Housings
MagnaGear Load Testing
 Introduction Schedule

Models Date Available

700K and 525K 12 to 16 weeks

390K / 285K 12 to 16 weeks

Base mounted
210K,140K and 100K 12 to 16 weeks

Delivery quoted upon

920K
request

Swing Base
MagnaGear XTR Collateral
• Data sheets & brochure are available

• Catalog will be developed for 3rd Quarter 2008

 MagnaGearXTR Mechanical Kw Ratings

Right Angle Reducers

MAGNAGEAR Right Angle Rating

Mechanical Kilowatt Rating @ 1.0 SF

High Speed Nominal Low Speed Size

Rpm Ratio Rpm 100 150 210 285 380 525 700 920
12.50 140 156 249 344 422 497 756 1,033 1,317
14.00 125 140 223 309 401 468 756 1,033 1,336
16.00 109 126 201 279 357 444 739 969 1,272
18.00 97 110 175 250 324 423 664 869 1,154
20.00 88 99 158 226 293 396 606 787 1,036
22.40 78 90 144 196 265 358 551 707 940
25.00 70 83 133 178 233 324 467 610 842
1750 28.00 63 74 118 161 217 277 425 553 728
31.50 56 67 107 148 196 247 386 496 660
35.50 49 60 96 131 178 222 349 455 591
40.00 44 52 83 115 155 203 314 414 534
45.00 39 46 74 102 139 183 283 373 476
50.00 35 44 70 95 124 165 257 334 438
56.00 31 39 63 87 115 148 229 296 398
63.00 28 36 57 79 104 130 209 272 363
Note: Shaded area is Triple Reduction.
MagnaGearXTR Mechanical Kw Ratings

Offset Parallel Reducers

MAGNAGEAR Parallel Shaft Rating
Mechanical Kilowatt Rating @ 1.0 SF

High Speed Nominal Low Speed Size

Rpm Ratio Rpm 100 150 210 285 380 525 700 920
8.00 219 230 366 507 701 954 1211 1676 2236
9.00 194 206 328 454 623 859 1123 1548 2075
10.00 175 186 297 411 568 789 1046 1427 1874
11.20 156 170 271 369 514 706 968 1280 1700
12.50 140 157 250 335 465 653 894 1162 1527
14.00 125 139 222 303 424 578 813 1044 1381
16.00 109 127 202 279 370 484 737 959 1243
18.00 97 114 181 247 333 439 663 873 1126
20.00 88 98 156 217 297 396 598 788 1004
1750 22.40 78 91 145 204 256 354 543 707 926
25.00 70 81 130 183 241 326 486 628 842
28.00 63 73 111 163 218 291 443 577 768
31.50 56 66 101 147 197 269 NA NA NA
35.50 49 60 92 132 179 238 NA NA NA
40.00 44 55 85 120 156 218 NA NA NA
45.00 39 49 75 108 140 198 NA NA NA
50.00 35 44 68 94 125 180 NA NA NA
56.00 31 40 61 88 116 162 NA NA NA
63.00 28 34 53 77 105 145 NA NA NA
Note: Shaded area is Triple Reduction.
MagnaGearXTR Torque Ratings

Right Angle Reducers

MAGNAGEAR Right Angle Rating

Torque Rating in N-m

High Speed Nominal Low Speed Size

Rpm Ratio Rpm 100 150 210 285 380 525 700 920
12.50 140 10,568 16,980 23,272 29,228 34,064 51,832 69,952 90,014
14.00 125 10,675 17,155 23,524 31,552 36,800 57,857 78,305 101,178
16.00 109 10,771 17,312 23,748 31,936 39,188 63,318 82,489 108,441
18.00 97 10,901 17,527 23,987 32,241 41,078 64,000 83,415 109,676
20.00 88 11,000 17,690 24,205 32,559 43,581 64,584 84,234 110,888
22.40 78 11,093 17,842 24,538 32,879 42,878 65,179 85,125 111,958
25.00 70 11,178 17,982 24,774 32,217 44,411 66,196 86,315 113,166
1750 28.00 63 11,304 18,190 25,022 33,485 44,077 66,758 87,104 114,723
31.50 56 11,403 18,353 25,226 33,794 42,756 67,330 87,961 115,752
35.50 49 11,520 18,545 25,526 34,073 44,095 67,923 88,629 116,914
40.00 44 11,678 18,800 25,849 34,477 44,290 68,543 89,361 117,942
45.00 39 11,795 18,994 26,130 34,789 44,127 69,148 90,152 119,124
50.00 35 11,854 19,091 26,293 35,121 44,299 69,700 90,986 119,954
56.00 31 11,951 19,250 26,495 35,327 44,525 70,336 91,877 120,905
63.00 28 12,041 19,394 26,688 34,614 44,199 70,856 92,508 121,821
Note: Shaded area is Triple Reduction.
MagnaGear XTR Torque Ratings

Offset Parallel Reducers

MAGNAGEAR Parallel Shaft Rating
Torque Rating in N-m

High Speed Nominal Low Speed Size

Rpm Ratio Rpm 100 150 210 285 380 525 700 920
8.00 219 10,128 16,257 22,253 29,658 40,351 54,076 73,900 99,505
9.00 194 10,250 16,461 22,538 30,066 40,855 55,957 76,444 102,337
10.00 175 10,373 16,662 22,826 30,390 41,255 58,349 79,099 104,028
11.20 156 10,477 16,831 23,111 30,728 41,779 60,740 80,064 105,194
12.50 140 10,563 16,971 23,343 31,068 42,139 62,073 80,919 106,458
14.00 125 10,679 17,161 23,567 31,374 42,699 62,694 81,849 107,111
16.00 109 10,765 17,303 23,744 31,817 43,494 63,337 82,574 108,835
18.00 97 10,866 17,470 24,007 32,160 43,919 64,009 83,368 109,950
20.00 88 11,010 17,707 24,302 32,523 44,368 64,664 84,224 111,230
1750 22.40 78 11,083 17,826 24,440 32,981 44,845 65,262 85,128 112,129
25.00 70 11,203 18,022 24,708 33,164 45,159 65,949 86,091 113,159
28.00 63 11,321 18,286 24,982 33,472 45,718 66,510 86,772 114,149
31.50 56 11,431 18,466 25,239 33,781 46,045 NA NA NA
35.50 49 11,529 18,628 25,513 34,060 46,552 NA NA NA
40.00 44 11,617 18,771 25,754 34,464 46,906 NA NA NA
45.00 39 11,742 18,972 25,996 34,777 47,274 NA NA NA
50.00 35 11,836 19,124 26,325 35,108 47,660 NA NA NA
56.00 31 11,941 19,294 26,461 35,315 48,068 NA NA NA
63.00 28 12,078 19,511 26,740 34,599 48,502 NA NA NA
Applications

Where:

• Mining, Aggregate, Power Plants,

Wood Products, Grain

What:

• Conveyors
• Bucket Elevators
• Sizers
• Crushers
• Feeders
• Carriage Drive
• Breakers
Questions?