BLACKMER HRB User manual

BLACKMER PARTS LIST 960267
Page 1of 4PARTS LIST
109-C00
With Installation and Maintenance Instructions Section 109
HELICAL GEAR REDUCERS MODEL: HRB Effective Mar 2014
(Refer to GX Parts List 101-B04 for Reducer Model HRB-GX) Replaces Mar 2013
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the product, or in the manual,
look for one of the following signal words and be alert to the
potential for personal injury, death or major property
damage
Warns of hazards that WILL cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
NOTICE:
Indicates special instructions which are very
important and must be followed.
NOTICE:
Blackmer gear reducers MUST only be installed in systems,
which have been designed by qualified engineering
personnel. The system MUST conform to all applicable
local and national regulations and safety standards.
These instructions are intended to assist in the installation of
and maintenance of the Blackmer gear reducer, and MUST
be kept with the reducer.
Blackmer gear reducer service shall be performed by
qualified technicians ONLY. Service shall conform to all
applicable local and national regulations and safety
standards.
Thoroughly review this manual, all instructions and hazard
warnings, BEFORE performing any work on Blackmer gear
reducer.
Maintain ALL system and Blackmer pump and reducer
operation and hazard warning decals.
NOTICE:
Pump manuals, parts lists and other needed
literature may be obtained from the Blackmer
website (www.blackmer.com) or by contacting
Blackmer Customer Service.
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
or death
Hazardous voltage.
Can shock, burn or
cause death.
If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior
to performing service or maintenance
Hazardous or toxic
fluids can cause
serious injury.
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage
Hazardous pressure can
cause personal injury or
property damage
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death.
Hazardous machinery
can cause serious
personal injury.
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause severe
personal injury or property damage.
Hazardous pressure can
cause severe personal
injury or property
damage
Failure to allow gear reducer to cool
before attempting maintenance can
cause serious personal injury.
Extreme heat can
cause injury or
property damage.
NOTE: Numbers in parentheses following individual parts
indicate reference numbers on the corresponding Lip Seal
Parts Lists.

Blackmer 109-C00 Page 2 of 4
Ref. No. Description Parts
per Unit Part No. Ref. No. Description Parts
per Unit Part No.
24 Bearing 2 903130 124 Key – Gear 1 909179
24A Bearing 2 903150 124A Key – Shaft 1 909182
29 Oil Level Plug 1 908198 125 Shaft 1 704021
29A Drain Plug 2 908100 149 Eyebolt 1 922450
35 Key – Pinion 1 909177 154 Bushing 1 908794
38 Dowel Pin 2 930739 BRACKET ASSEMBLY 871085
76C Fill & Vent Plug 1 701988 108A Bracket Ring 1 834018
82 Spacer Ring 2 374011 108B Bracket Stud 6 921534
101 Gear 1 See Table 108C Lockwasher 10 909630
102 Pinion & Shaft 1 See Table 108D Nut (1/2 – 13) 10 922850
104 Oil Seal 1 331930 108E Torque Arm (Stud) 1 921584
104A Oil Seal 1 331909 108F Eyebolt 1 922474
110 Body/Cover Assembly11 894011 108G Plain Washers (1/2″) 3 909670
111 Gasket – Cover 1 814010 108H Nut (3/8 – 24) 6 922843
112 Capscrews – Cover 12 920384 108K Setscrew 6 922204
114 Closure Plate – Input 1 * 108L Mounting Bracket 1 834031
115 Gasket – Input Closure Plate 1 814011 108M Slider Post 2 834030
116 Capscrews – Closure Plate 12 920073 108N Foot 1 834028
119 Closure Plate – Blind 1 * 108P Pipe Cap 2 344001
119A Gasket – Blind Closure Plate 1 814012
* Non-saleable item – included in Body/Cover Assembly.
1 Body/Cover Assembly includes Ref. Nos. 38, 110, 111, 112, 114, 115, 116, 119, 119A.
GEAR AND PINION SELECTION TABLE
RATIO RPM 102 PINION NO. QTY. 101 GEAR NO. QTY.
2.70 640 915148 1 919948 1
3.52 500 915134 1 919934 1
4.36 400 915135 1 919935 1
5.77 300 915136 1 919936 1
7.71 230 915137 1 919937 1
9.18 190 915149 1 919949 1
NOTE: Speed is based on 1750 rpm input.

Blackmer 109-C00 Page 3 of 4
INSTALLATION
NOTICE
This product must only be installed in systems which
have been designed by those qualified to engineer such
systems. The system must be in accordance with all
applicable regulations and safety codes and warn of any
hazards unique to the particular system.
ALIGNMENT ADJUSTMENT
The gear reducer can be moved vertically on its bracket
mount to raise or lower the output shaft (slow speed shaft) to
align with the pump shaft.
The reducer can also be rotated on the bracket ring to
facilitate both horizontal and vertical alignment of the input
shaft (high speed shaft) to the motor shaft. This flexibility in
movement eliminates the need for shims under the motor or
driver in most cases. NOTE: Refer to Blackmer Dimensions
109-103 for maximum variation of shaft alignment to maintain
proper gear reducer lubrication.
Follow these steps to align the reducer:
1. Align the output shaft to the pump shaft by loosening the
four (4) setscrews (108K) and locknuts in the mounting
bracket (108L), enabling the reducer to slide freely on the
slider posts.
2. Once the proper alignment is determined, retighten the
setscrews and locknuts. Leave the torque arm locknuts
loosened for the next step.
3. Align the input shaft to the motor shaft by loosening the
four (4) bracket nuts (108D) in the bracket ring (108A)
enabling the reducer to rotate freely. If the reducer sticks
on the mounting bracket, tap it lightly with a mallet.
4. After obtaining the correct alignment, be sure to retighten
the bracket nuts and the upper and lower locknuts of the
torque arm.
COUPLING ALIGNMENT
Both angular and parallel coupling alignment MUST be
maintained between the pump, gear, motor, etc. in
accordance with manufacturer’s instructions. Verify coupling
alignment after installation of new or rebuilt pumps. See fig. 1.
1. Parallel alignment: The use of a laser alignment tool or dial
indicator is preferred. If a laser alignment tool or dial indicator
is not available, use a straightedge. Turn both shafts by hand,
checking the reading through one complete revolution.
Maximum offset must be less than .005” (125 microns).
2. Angular alignment: Insert a feeler gauge between the
coupling halves. Check the spacing at 90º increments around
the coupling (four check points). Maximum variation must not
exceed .005” (125 microns). Some laser alignment tools will
check angular alignment as well.
3. Replace the coupling guards after setting alignment.
MAINTENANCE
NOTICE:
Maintenance and troubleshooting must be done by an
individual experienced with pump and reducer
maintenance and the type of system involved.
NOTICE:
To avoid possible entanglement in moving parts do not
lubricate pump bearings, gear reducer or any other parts
while the pump is running.
CAUTION: The normal full load operating temperature of the
gearcase is 180ºF (82ºC) – too hot to touch with the bare hand.
LUBRICATION
Gear reducers are not lubricated at the factory. Oil MUST
be added before starting the pump.
Horsepower calculations for Blackmer reducers are based on
75°F (24°C) ambient air temperature; 200°F (93°C) maximum
oil temperature using synthetic oil.
Blackmer recommends using synthetic oil with oxidation
inhibitors and is compatible with Buna elastomers. Use
synthetic oil AGMA Viscosity Grade 4 or ISO Viscosity Grade
150 such as Mobil SHC 629, Mobil SHC 630, Shell Omala S4
GX 150, Castrol Isolube EP 150 or equivalent.
To add oil to the gear reducer:
1. Remove the oil level plug (29) and the fill and vent plug
(76C). NOTE: The vent fitting in the fill plug (76C) should
be kept clean to prevent expansion from forcing oil leaks at
the shaft.
2. Add oil through the filler hole until oil runs out of the oil level
hole – approximately 1.25 qt. (1.18 l) depending on the
orientation of the reducer mounting.
3. Replace the oil level plug and the fill and vent plug.
4. After the first two weeks of operation, the oil should be
drained, the gearcase flushed, and new oil added.
For normal operation, the oil should be changed every six
months or 1000 hours, whichever is shorter. If operation is
accompanied by frequent and wide changes in temperature,
or if the unit operates in an unusually moist or dusty
atmosphere, the oil should be changed every 500 hours or
every three months. NOTE: To maintain proper gear reducer
lubrication, refer to Blackmer Dimensions 109-103 for
maximum variation of shaft alignment.
REDUCER DISASSEMBLY
The gearcase on the bracket mounted gear reducer can
usually be removed from its bracket without disturbing the
motor or pump mounting.
1. Take apart the couplings and remove the six bracket nuts
(108D) and lockwashers (108C) from the bracket ring. Also
remove the upper locknut and lockwasher from the torque
arm (108E).
2. Once the bracket nuts are removed, rotate the gearcase on
the bracket and swing the input shaft away from the motor.
3. The gear reducer can then be lifted off the pump with the
bracket ring and studs still intact.

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4. Remove the twelve hex-head cover capscrews (112).
NOTE: The gearcase cover is located on the gearcase with
two (2) dowel pins (38). These pins remain in the gearcase.
5. After the capscrews have been removed, insert a wedge
between the projecting lugs on the gearcase cover and
tap lightly until the cover loosens and can be removed
from the casing.
6. Remove the cover gasket (111).
7. The pinion & shaft (input shaft) (102) is a one-piece
assembly and does not come apart. If necessary, the
bearings (24A) can be removed from the shaft with the use
of a bearing puller or arbor press.
8. To remove the gear (101) and bearings (24) from the
output shaft (125), use a gear puller or arbor press. Support
the assembly on the gear and press the shaft out of the
gear and one bearing only. The second bearing must come
off in the other direction because of the shoulder on the
shaft.
OIL SEAL REPLACEMENT
1. To replace the oil seal (104A) on the input shaft, it is only
necessary to remove the closure plate (114). Once the
plate is removed, the old seal can be pressed out and a
new one installed. Grease the lip of the oil seal before
installing. The oil seal must be inserted such that the lip of
the seal will face inward when the closure plate is
reattached to the gearcase cover.
2. To replace the oil seal (104) on the output shaft, it is
necessary to disassemble the body and cover assembly
and remove the output shaft. (Refer to “Reducer
Disassembly.”) Grease the lip of the oil seal and insert it
into the bearing bore of the gearcase so that the lip of the
seal faces inward.
REDUCER ASSEMBLY
Before reassembling the gear reducer, clean each part
thoroughly. Wash out the bearing bores and remove all burrs
or sharp corners with a file.
NOTE: Disregard steps 1 and 2 if the shaft and bearing
assemblies have not been dismantled.
1. The output shaft (125) has a stepped shoulder where the
gear must be located.
a. Before installing the gear and bearings, remove all
dirt, burrs, or sharp corners from the shaft to prevent
galling or seizing of the gear and shaft.
b. Apply a coat of graphite, molysulphide, or white lead
to the shaft.
c. Press the short end of the shaft (125) squarely into the
bearing (24), and install the spacer ring (82).
d. Align the gear key (124) with the notch in the gear,
and press the gear (101) squarely onto the shaft.
e. Add a spacer ring (82) and press the second bearing
(24) onto the shaft.
2. Prior to installing the bearings, follow steps 1a and 1b. To
assemble the input shaft (102) (Pinion & Shaft), press a
bearing (24A) onto each end of the shaft.
3. After the shafts, gears and bearings have been
assembled, apply a light film of oil in the bearing bores of
the gearcase to help the bearings slide into position.
4. If the oil seal (104) has been removed from the gearcase,
it must be replaced prior to reassembly. Refer to step 2 of
“Oil Seal Replacement.”
5. To install the shaft assemblies into the gearcase it is
easiest to tip the gearcase so that it is resting on the
bracket studs with the cavity opening upward.
a. Start the output shaft (125) into the bearing bore of the
gearcase.
b. Align the bearings and gear teeth of the input shaft
(102) with the output shaft and drop the two shaft
assemblies together into their respective bearing
bores.
NOTE: It is important to line the bearings up squarely with
the bores in order for them to drop smoothly into place. If
the bearings are positioned correctly in the gearcase, the
shafts should rotate freely when turned by hand.
6. Once the input and output shaft assemblies are properly
installed, set the cover gasket (111) on the gearcase.
7. Position the cover on the gearcase using the dowel pins
for alignment.
8. Install and tighten the cover capscrews (112).
9. Make sure the oil seal (104A) is inserted in the closure
plate (114) before reattaching the plate to the gearcase
cover. Refer to step 1 of “Oil Seal Replacement.”
10. Attach the closure plate gasket (115) and the closure
plate (114) to the gearcase cover
TROUBLESHOOTING
NOISE AND VIBRATION
POSSIBLE CAUSES: REMEDY:
1. Worn or damaged bearings. Replace bearings.
2. Inadequate lubrication / use of wrong
lubricant.
Check oil condition. The lubricant may not be getting to the contact areas of the
gear teeth, or the viscosity of the oil may be too low for the operating
temperature (see “Lubrication”).
3. Impurities in the lubricant, such as
abrasive particles. Replace with clean oil (see “Lubrication”)
4. Excessive overloading.
Overloading causes overheating which may lower oil viscosity and thus cause
the oil film on gear teeth contact surfaces to break down. The gears will begin to
“groan” as the oil loses its effectiveness. If the loading is not decreased, the gear
teeth will begin to “bite” into each other and wear out rapidly.
5. Misalignment to either pump or motor. Recheck alignment and adjust as necessary.