MagnaGear XTR®
Gear Reducer
Built to handle the toughest environments and provide maximum value
MagnaGear XTR is a power-dense reducer with premier reliability in a compact, heavy-duty package. Its planetary and helical gearing designs provide you with a compact solution that thrives in challenging environments—outlasting the competition to maximize your productivity.
Built to provide maximum uptime and long-term value, MagnaGear XTR includes best-in-class features to be the ideal solution for a wide range of bulk material handling applications—from mining to power production to grain to lumber processing.
Key features and benefits
- Supports drive packages up to 2,500 hp (2 MW)
- Options in 12 case sizes offering up to 3,500,000 lb-in of torque
- Offered in offset-parallel and right-angle configurations to maximize application versatility and optimize inventory
- Tunnel-housing design is self-aligning between the motor, coupling, and reducer to optimize performance and extended product life
- AGMA-rated design with heavy-duty bearings rated to last twice as long as the competition
- Available with patented twin-tapered bushing system for easy installation and guaranteed gearbox removal
- Extreme pressure lubricant-compatible backstop for maximum performance and reliability
- Purgeable, dual sealing system provides enhanced levels of protection for long-lasting reliability, even in harsh environments
- Premier HNBR sealing system to block contaminants in a wide range of operating temperatures
- Reliability kits available to maximize critical equipment uptime
- Easy-to-install bushing covers, shaft guards, and belt guards for protection from rotating equipment—accommodating OSHA and MSHA safety guidelines
Resources
Frequently asked questions (FAQs)
What mounting positions are approved for MagnaGear XTR reducers, and how should drains and breathers be set?
MagnaGear XTR reducers are typically installed in a horizontal mounting position for base-mounted or shaft-mounted configurations. For shaft-mounted units, a torque arm is required to secure the reducer while allowing movement with shaft runout. Drain, breather, and dipstick locations must match the mounting position to ensure oil flows correctly and internal components stay lubricated. For mounting positions other than horizontal, contact Dodge Application Engineering to confirm the correct oil level required.
What oil should I use in a MagnaGear XTR reducer, and how often should it be changed?
MagnaGear XTR reducer oil selection depends on ambient temperature, operating speed, and application conditions. Mineral-based extreme pressure (EP) gear oils are commonly used for standard conditions, while synthetic oils may be required for cold starts or extended service life. After initial startup, change the oil to remove break-in debris, then follow a typical interval of 2,500 hours or 6 months for mineral-based oil, or 8,000 hours or 18 months for synthetic oil. Regular oil condition monitoring is recommended, and oil change intervals may be adjusted based on monitoring results.
What information is needed to select a new or replacement MagnaGear XTR reducer?
To select a new or replacement MagnaGear XTR reducer, contact a Dodge sales engineer or our customer service team and provide the following: input speed and horsepower, required output speed or torque, mounting position, duty cycle, and operating environment details such as ambient temperature, humidity, dust exposure, and corrosive conditions. For replacements, also include the existing reducer model, ratio, and serial number. For shaft-mounted units, include the driven shaft diameter, length, and keyway configuration. Complete details help confirm ratings, fit, and whether adapters or accessory changes are required.
How should a shaft-mounted MagnaGear XTR reducer be installed and secured?
Shaft-mounted MagnaGear XTR reducers require a vertical torque arm with a flexible connection to ensure the unit can move slightly with shaft runout and load, preventing stress on the housing and protecting internal bearings and gearing. The torque arm should be properly sized and oriented per the installation manual to safely handle reaction torque under operating conditions.
Which reliability and monitoring upgrades are available for MagnaGear XTR reducers?
MagnaGear XTR reducers can be equipped with reliability kits that simplify filtration, oil sampling, and routine service access without opening the housing. The OPTIFY™ Breather adds desiccant filtration with condition monitoring, providing visibility into saturation, temperature, and service status to help extend oil life and reduce unplanned downtime on critical drivetrain assets.
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