BLACKMER HROF User manual

BLACKMER PARTS LIST 960265
Page 1of 4PARTS LIST
109-A00
With Installation and Maintenance Instructions Section 109
HELICAL GEAR REDUCERS MODEL: HROF Effective Mar 2013
(Refer to GX Parts List 101-B01 or 101-B02 for Reducer Model HRO-GX) Replaces Apr 2010
r140109
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 Page 109-A00 Page 2 of 4
Ref.
No. Description Parts per
Unit Part No. Ref.
No. Description Parts
per Unit Part No.
24 Bearing 1 903142 104 Oil Seal 2 331925
24A Bearing – Shielded 1 903143 104A Oil Seal 1 331921
24B Bearing 1 903116 110 Body/Cover Assembly11 894044
24C Bearing – Shielded 1 903117 111 Gasket – Cover 1 814040
29 Pipe Plug 1 908187 112 Capscrews – Cover (5/16 - 18 x 1") 5 920203
29A Drain Plug 1 908105 112A Capscrews – Cover (5/16 - 18 x 1 1/4") 2 920235
29B Pipe Plug 1 908198 114 Closure Plate 1 *
29D Oil Level Plug 1 908187 115 Gasket – Closure Plate 1 814042
35 Key – Pinion 1 909166 116 Capscrews – Closure Plate 5 920178
38 Dowel Pin 2 930739 124 Key – Gear 1 909164
76C Fill & Vent Plug 1 701988 124A Key – Shaft 1 909165
82 Spacer Ring 2 374041 125 Shaft 1 704051
82A Spacer Ring 1 374042 132 Elbow 1 908603
83 Retaining Ring 1 903603 132A Nipple 1 908302
101 Gear 1 See Table 132B Street Elbow 1 908573
102 Pinion & Shaft 1 See Table 154 Bushing 1 908794
* Non-saleable item – included with Body/Cover Assembly.
1Body/Cover Assembly includes Ref. Nos. 38, 110, 111, 112, 112A, 114, 115, 116.
GEAR AND PINION SELECTION TABLE
RATIO RPM 102 PINION NO. QTY. 101 GEAR NO. QTY.
2.24 780 915118 1 919918 1
2.72 640 915116 1 919916 1
3.32 520 915117 1 919917 1
4.10 420 915120 1 919920 1
4.94 350 915121 1 919921 1
NOTE: Speed is based on 1750 rpm input.

Blackmer Page 109-A00 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
To adjust the alignment of the gear reducer to the pump or
motor, use shims as needed.
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 (29D) 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 0.5 qt. (0.47 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.
REDUCER DISASSEMBLY
The foot mounted gear reducer can usually be removed from
its unit assembly without disturbing the motor or pump
mounting.
1. Take apart the couplings and remove the capscrews in the
foot mount.
2. Once the couplings are apart and the capscrews are
removed, the reducer can be lifted away from the pump
and motor.
3. Remove the cover capscrews (112 & 112A). NOTE: The
gearcase cover is located on the gearcase with two (2)
dowel pins (38). These pins remain in the gearcase.
4. 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.
5. Remove the cover gasket (111).
6. The pinion & shaft (input shaft) (102) is a one-piece
assembly and does not come apart. If necessary, the
bearings (24 & 24A) can be removed from the shaft with
the use of a bearing puller or arbor press.
7. To remove the gear (101) and bearings (24B & 24C) 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 bearings.

1809 Century Avenue, Grand Rapids, Michigan 49503-1530, U.S.A.
Telephone: [phone] / Fax: [phone]-A00
E-Mail: [email protected] / Internet: www.blackmer.com Page 4 of 4
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 two (2) oil seals (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 one oil seal and insert it
into the bearing bore of the gearcase so that the lip of the
seal faces inward. Install the spacer ring (82A) and insert
the second oil seal also with the lip facing 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 on one end
(retaining ring end) to facilitate bearing and gear location.
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 retaining ring end of the shaft squarely into
the shielded bearing (24B). The shield of the bearing
should be upward, so that the balls of the bearing will
face the gear.
d. Install the spacer ring (82).
e. Align the gear key (124) with the notch in the gear
(101), and press the gear squarely onto the shaft.
Install the other spacer ring (82).
f. Press the second bearing (24C) squarely onto the
shaft and add the retaining ring (83).
2. To assemble the input shaft (102) (Pinion & Shaft) a
bearing must be pressed onto each end of the shaft.
a. Prior to installing the bearings, follow steps 1a and 1b.
b. Press the shielded bearing (24A) onto the driven end
of the shaft (longer end) with the shield facing
downward so that the balls of the bearing will face the
pinion.
c. Press the second bearing (24) onto the opposite shaft
end.
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 seals (104) have been removed from the
gearcase, they 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
closed end, 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. Set the closure plate gasket (115) and the closure plate
(114) on the gearcase cover. Install and tighten the
remaining two (2) cover capscrews (112A), and the five
(5) closure plate capscrews (116).
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.