TECHNICAL SERVICE MANUAL
Contents
1. A Unit of IDEX Corporation Cedar Falls IA 50613 USA2. B AND C SIZE REDUCERS SIZE PART NUMBER RATIO 3 551 049 224 224 1 A SURES B SIZE HELICAL GEAR REDUCER 3 551 054 187 1 87 1 3 551 055 224 2 24 1 3 551 001 276 2 76 1 C SIZE HELICAL GEAR REDUCER CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA HELICAL REDUCER HIGH SPEED LOW SPEED COUPLING COUPLING BASEPLATE NOTE UNIT FURNISHED WITH COUPLING GUARDS AS STANDARD FIGURE 4 TYPICAL INSTALLATION SPECIAL INFORMATION LUBRICATION BREATHER VENT OIL FILLHOLE LOWER HOLE OIL LEVEL PLUG A REDUCER DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc or drive equipment be sure Y 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or LOWER HOLE OIL LEVEL DRAIN PLUG m FIGURE 5 2 That the driving means motor turbine engine etc has been locked out or made non VIKING GEAR REDUCERS ARE SHIPPED WITHOUT OIL operational so that it cannot be started while work BEFORE OPERATING THE REDUCER BE SURE TO is being done on pump ADD THE PROPER AMOUNT AND TYPE OF LUBRICANT CAUTION DO NOT OVER FILL See chart blow 3 That you know what liquid the pump has been handling or in the reducer and the precautions necessary to safely handle the liquid Obtain a SIZE SERVICE material s
3. Gear Ratios Four different gear ratios are available for the A size Reducers Eight ratios are available for B size reducers and seven ratios for C size reducers Complete reducers within a size may be interchanged on a Viking pump unit to obtain desired pump speeds and capacities Gear ratios may be changed in all reducers within each size by selecting the proper pinion and gear of a common ratio A pinion from one ratio cannot be used with a gear from a different ratio Certain B and C reducers require additional or different parts besides the pinion and gear to make the ratio change See the chart below for changes required RATIO CHANGES REQUIRED Snap ring for pinion and shaft 6 27 to 1 Two spacers A larger O D than is used 7 65 to 1 h on other ratios and gear shaft 795 to 1 cia shaft and a longer key also a snap NOTE SNAP RING IS FURNISHED WITH C 7 95 TO 1 PINION AND SHAFT When changing the reducer ratio the nameplate should also be changed to new ratio reducer part number After making any output or input speed change complete reducer or gear ratio changes a check should be made to ensure the couplings are of sufficient size for the conditions which reducer will be operating For ratios available see page 1 of this manual catalog specification sheet or consult factory or Viking representative DISASSEMBLY Before starting disassembly study the exploded view see Fig 7 8
4. gear case half opposite the gear shaft extension 090 below the surface of the gear case NOTE Coat the side of the covers with sealer and drive the cover from the inside of case towards outside of case ISSUE G PAGE 4 OF 8 10 11 12 13 Apply lubricant to the lip seal sealing surfaces Block the gear case open side up to provide at least 2 clearance between the case and the assembly bench Make certain the pinion and gear shaft keyways are free of burrs and sharp edges to prevent damaging the sealing surfaces in the lip seals Take the pinion and gear assemblies mesh the gear teeth and insert simultaneously into the gear case half Rotate the gear shaft slightly as it is pushed through the lip seal Tap the end of pinion shaft and gear shaft with a hard wood block to seat the bearings in the counterbores Place gasket on the gear case If the gasket is damaged discard it and use a new gasket Align the gear case half with ends of the pinion and gear shafts and carefully pass the other half into place Rotate the pinion shaft during assembly Tap the gear case with a hard wood block to seat the bearings Install the six capscrews and nuts and tighten securely alternating around gear case to prevent distortion Install drain plug Be sure the proper amount and type of lubricant is added See Lubrication instructions page 2 ASSEMBLY B Reducer Assembly See Fig 8 18 19 FIGURE 8
5. or 9 for the particular size reducer that is being disassembled to help determine parts relationship The parts are indexed in a logical sequence of disassembly and will prove to be a valuable aid in dismantling the reducer 1 Disconnect the couplings and remove the capscrews holding the mounting bracket to the base Remove the coupling halves and bracket from the reducer 2 Remove the breather and drain plugs Drain all lubricant from the reducer Remove the capscrews from the gear case halves 4 Tap firmly and alternately on the gear shaft and pinion shaft This will separate the reducer halves 5 With two screwdrivers at opposite sides carefully pry the reducer cover loose from internal ball bearings DO NOT FORCE Be careful not to damage the gasket or gasket surface 6 Grasp the pinion and gear shafts and pull both assemblies simultaneously from the case or cover 7 Use a conventional gear or bearing puller to remover the bearing from gear shaft Remove the bevelled spacer on B and C size reducers Press the shaft from the gear 8 Use a puller and remove bearings from the pinion shaft Remove the spacer from B size 7 65 to 1 ratio from the pinion shaft 9 Remove the lip seals from the gear case halves cover and case only if they show signs of deterioration or damage Lip seals must be pressed or driven out from the inside of gear case and cover on B and C reducers A size reduc
6. seal Tap end of the pinion shaft and the spacer gear shaft with hardwood block to seat the bearings in 2 Install the square key in the gear shaft and press the gear counter bores into place Be sure the gear seats against the shoulderon 7 Place gasket on the gear case If the gasket is damaged the shaft discard it and use a new gasket 3 Place the spacer on the gear shaft with the bevelled edge 8 Align the gear case cover with the ends of pinion and gear toward the gear Install the bearing over the gear shaft and shafts and carefully push the cover into place Rotate seat firmly against the spacer Install a second bearing on the pinion shaft during assembly Tap the cover with a the large end of the gear shaft and seat the bearing firmly hardwood block to seat the bearings in the cover against the shaft shoulder 9 Install the seven capscrews and nuts and tighten securely the gear case and cover gaskets face down on a surface which will not mar the face Be sure the snap rings are in 10 Install the drain plug Be sure the reducer is filled with the the face and cover Put gasket sealer on the O D of the proper lubricant See Lubrication instructions page 2 SECTION TSM 610 ISSUE G PAGE 5 OF 8 ASSEMBLY C Reducer Assembly See Fig 9 FIGURE 9 C SIZE HELICAL GEAR REDUCER EXPLODED VIEW ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART Drain Plug Gear Shaft 2 Breather dL Ball Bearing D
7. B SIZE HELICAL GEAR REDUCER EXPLODED VIEW 5 Nut Setz7 sony as ky Ja oarcase O Oooo Dowel Pin Locating Set2 16 Gerst pooo r Gear case cover a7 ease Do e ese s eaen Oo 1 2 3 14 15 16 17 1 Install the ball bearing on the pinion and shaft Be sure lip seals Drive new lip seals with lip toward the inside of the bearings are seated firmly against the shoulders on the reducer in place against the snap rings Use a wood the shaft block covering entire lip seal and drive evenly Apply NOTE The B reducer with 6 27 to 1 ratio requires a snap origan p Sea pUNACES ring This snap ring must be installed in the groove on the 5 Block the gear case open side up to provide at least 374 shaft prior to bearing assembly The bearing should be clearance between the case and the assembly bench seated against the snap ring 6 Make certain the pinion and gear shaft keyways are free The B reducer with 7 65 to 1 ratio requires two spacers of burrs and sharp edges to prevent damaging the lip seal one on the pinion and shaft and one on the gear shaft sealing surfaces Take the pinion and gear assemblies The spacer for the pinion and shaft should be installed mesh the gear teeth and insert simultaneously into with bevelled edge toward bearing Install the ball bearing the gear case half Rotate the gear shaft slightly as it is on the pinion and shaft seating the bearing firmly against pushed through lip
8. Electronic copies of the most current TSM issue can be found on the Viking Pump website at www vikingpump com TECHNICAL SERVICE MANUAL section tsm 610 PAGE 1 VIKING HELICAL GEAR REDUCERS A B AND Cc SIZES ISSUE F CONTENTS EOC CUON cise Ti 1 Special INFOrMALION cccceccceeeccceseeeeceeeeceeeeeseeeeeseeeeeeees 2 Lubrication eseeseeeeneneenernererrererrerrrrsrrnrerrerrrrnrrnrnrrrrerrerrernns 2 AVS Eel ROMA tans hart veoesarchearas eapuntecatambatatunenesesiniascasdabyerscutsntaas ies 3 Operation Deeet nee eee ee eee ee ee ee ee ee ee ee 3 IGASSEMONY sanicscsciensiascaarteesansdeasatiashcsausetencdabaenssuiacuonana cain 3 Assembly A REdUCET aoaieceacetegedeceeak unera aTa NAN ASER 4 B RECUCED ccccceceeecceeceeeeeeeeeeeeeneeeeeeneeeeeeeeeeeeeeaeeeeees 5 C Red CE fe auton inieecstat coves bt ices cs edeansan tienes seca 6 Technical Data aesicsarssnertencdviessseznnneteindsediecdiecicbaaacoseiiavencteaas T CUREA WAAN asinn EE 8 A SIZE HELICAL GEAR REDUCER INTRODUCTION The illustrations used in this manual are for identification purposes only and cannot be used for ordering parts Obtain a parts list from the factory or a Viking representative Always give the complete name of the repair part and part number along with the reducer part number when ordering repair parts The reducer part number is stamped on the nameplate UNMOUNTED PUMP AND UNIT MODEL NUMBERS A
9. afety data sheet MSDS for the liquid to be sure these precautions are understood 3 8 PT 6 OZ 1 2 PT 8 OZ Use SAE 30 Above 32 F Use SAE 10W Below 32 F 1 Remove the breather and add the proper lubricant for the type of service and quantity given after each size reducer 4 Before starting unit or reducer be sure all drive equipment guards are in place Failure to follow above listed precautionary mea sures may result in serious injury or death 2 After the first 100 hours of operation drain and refill with new lubricant 3 Check the lubricant level every 2000 hours of operation or every six months which ever occurs first Add lubricant as necessary 4 Once each year drain and refill If the reducer is outdoors change to proper lubricant each spring and fall SECTION TSM 610 ISSUE G PAGE 2 OF 8 INSTALLATION Viking helical gear reducers are shipped completely assembled and ready for installation except for the addition of lubricant 1 Fasten the pump securely to the baseplate 2 Mount the reducer on the reducer bracket finger tight The breather cap should be located on the upper side of the reducer and drain plug on the bottom 3 Place the coupling halves on the high and low speed reducer shafts 4 Align the low speed shaft coupling half with the coupling half on the pump or driver shaft Use a straight edge to align the coupling as in figure 6 AC clamp clamped over pieces of keys
10. at the Install the square key in the gear shaft and press the gear ee atin en Mie EEG into place Be sure the gear seats against the shoulderon 7 Place the gasket on gear case If the gasket is damaged the shaft discard it and use a new gasket Place the spacer on the gear shaft with bevelled edge 8 Align the gear case cover with the ends of the pinion toward the gear Install the bearing over gear shaft and and gear shafts and carefully push the cover into place seat firmly against the spacer Install a second bearing Rotate the pinion shaft during assembly Tap the cover on large end of the gear shaft and seat the bearing firmly with a hardwood block to seat the bearings in cover i he shaft shoulder ea nal onouieel 9 Install the seven capscrews and nuts and tighten If the lip seals have been removed during disassembly securely alternating around the gear case to prevent place gear case and cover gaskets face down on surface distortion hich will h i i A O A E ed ee apnea 10 Install the drain plug Be sure the reducer is filled with proper lubricant See Lubrication instructions page 2 SELECTING THE CORRECT VIKING 1 Determine ratio to obtain desired output speed Determine actual horsepower requirements of application Determine equivalent horsepower for the application by HELICAL GEAR REDUCER This service factor takes into account the time length of service per day the load classification uniform modera
11. er may have lip seals pressed in or out from either side of gear case half SECTION TSM 610 ISSUE G PAGE 3 OF 8 SECTION TSM 610 ASSEMBLY A Reducer Assembly See Fig 7 FIGURE 7 A SIZE HELICAL GEAR REDUCER EXPLODED VIEW ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 3o Capscrew Set 6 8 Ball Bearing Set 4 Lip Seal Set 2 Nut Set 6 9o Gear Cover Set 2 fs owein sea o ey SOSC sSC Install ball bearings on the pinion shaft Be sure the single row bearingsare seatedfirmly against the shoulders on the pinion shaft Install the square key in the gear shaft and press the gear into place Be sure the gear is centered on the shaft Install the ball bearings on each side of the gear Be sure the bearings are seated firmly against the gear and the shaft is still centered If the lip seal has been removed during disassembly place the gear case halves gasket faces down on a surface which will not mar the face Put gasket sealer on O D of lip seals Drive new lip seals into the gear case halves lip towards inside of reducer with a wood block covering entire lip seal Drive evenly until the lip seals are flush with the outer face of the gear case halves If steel covers have been removed during disassembly install one cover in the bore of the gear case half opposite the pinion shaft extension This cover should be flush with outer edge of case Install a second cover in the bore of the
12. ouble Row Ball Bearing Double Row Pipe Plug Set 2 Ball Bearing Single Row Ball Bearing Single Row Spacer Capscrew Set 2 Spacer Pinion and Shaft Dowel Pin Locating Set 2 Snap Ring Set 2 6 Gear Case Cover Lip Seal Set 2 SECTION TSM 610 the face and cover Put gasket sealer on the O D of lip seals Drive new lip seals with lip toward the inside of the reducer in place against the snap rings Use a wood block covering entire lip seal and drive evenly Apply lubricant to lip seal surfaces ISSUE G PAGE 6 OF 8 Install the ball bearing on the pinion shaft the double row 5 Block the gear case open side up to provide at least bearing on the small diameter end and the single row 3 clearance between case and assembly bench bearing on the large diameter end Be sure the bearings l a are seated firmly against the shoulders on the shaft Oe Mane a A oial Key aye on Nee of burrs and sharp edges to prevent damaging the lip seal NOTE The pinion and shaft for C reducer 7 95 to 1 sealing surfaces Take the pinion and gear assemblies ratio is furnished with a snap ring This snap ring must mesh the gear teeth and insert simultaneously into the be installed in the groove on the shaft prior to bearing gear case half Rotate the gear shaft slightly as it is assembly The bearing should be seated against the snap pushed through the lip seal Tap the end of the pinion ring shaft and gear shaft with hardwood block to se
13. p provided that in no event shall this warranty extend more than eighteen 18 months from the date of shipment from Viking The warranty period for Universal Seal series pumps ONLY Universal Seal models listed below is three 3 years from date of startup provided that in no event shall this warranty extend more than forty two 42 months from the date of shipment from Viking UNDER NO CIRCUMSTANCES SHALL VIKING BE LIABLE UNDER THIS WARRANTY OR OTHERWISE FOR SPECIAL INCIDENTAL INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST OR UNREALIZED SALES REVENUES PROFITS INCOME COST SAVINGS OR BUSINESS LOST OR UNREALIZED CONTRACTS LOSS OF GOODWILL DAMAGE TO REPUTATION LOSS OF PROPERTY LOSS OF INFORMATION OR DATA LOSS OF PRODUCTION DOWNTIME OR INCREASED COSTS IN CONNECTION WITH ANY PRODUCT EVEN IF VIKING HAS BEEN ADVISED OR PLACED ON NOTICE OF THE POSSIBILITY OF SUCH DAMAGES AND NOTWITHSTANDING THE FAILURE OF ANY ESSENTIAL PURPOSE OF ANY PRODUCT THIS WARRANTY IS AND SHALL BE VIKING S SOLE AND EXCLUSIVE WARRANTY AND SHALL BE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ALL WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND NON INFRINGEMENT ALL OF WHICH OTHER WARRANTIES ARE EXPRESSLY EXCLUDED See complete warranty at www vikingopump com 3 2013 Viking Pump Inc All rights reserved CORPORATION VIKING PUMP INC
14. peeds higher than 1750 RPM consult the factory VIKING GEAR REDUCER RATIOS A SIZE MAXIMUM REDUCER HP B Size Helical Reducer Horsepower Table Part No Ratio 3 551 054 187 1 87 1 3 551 055 224 2 24 1 3 551 001 276 2 76 1 3 551 002 340 3 40 1 3 551 003 419 4 19 1 3 551 004 506 5 06 1 3 551 005 627 6 27 1 3 551 007 765 7 65 1 VIKING GEAR REDUCER RATIOS B SIZE Oe o HIGH SPEED SHAFT INPUT RPM 1750 1450 2 2 780 o s2 420 350 200 78 640 ie 64 52 420 190 0 o 0 0 16 5 950 Za 520 15 5 1 For input speeds higher than 1750 RPM consult the factory 0 5 0 0 28 8 5 23 190 7 3 SECTION TSM 610 ISSUE G PAGE 7 OF 8 TECHNICAL SERVICE MANUAL section sm 610 PAGE 8 VIKING HELICAL GEAR REDUCERS ssu A B AND C SIZES C Size Helical Reducer Horsepower Table Part No Ratio 3 551 056 221 2 21 1 3 551 008 331 3 31 1 3 551 009 421 4 21 1 3 551 010 508 5 08 1 3 551 011 624 6 24 1 3 551 012 795 795 1 3 551 032 280 2 80 1 HIGH SPEED VIKING GEAR REDUCER RATIOS C SIZE SHAFT o s 200 520 4 4 5 280 2290 16 7 640 520 20 0 2 520 16 7 1 For input speeds higher than 1750 RPM consult the factory VIKING PUMP IREX WARRANTY Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one 1 year from date of startu
15. te shock heavy shock and the type of drive Refer to the recommended maximum reducer horsepower multiplying the actual horsepower to be transmitted by the appropriate service factors which can be obtained in the Service Factor Table below line in the horsepower tables below and make sure the equivalent horsepower for a given input speed and ratio is less than or equivalent to the maximum recommended horsepower shown in the chart Service Factor Table CHARACTER OF INTERMITTENT 8 10 HRS 1 3 POWER SOURCE DRIVEN LOAD UP TO 3 HRS A DAY A DAY Electric Motor 8 Steam Turbine or 24 HRS A DAY 1 25 1 5 1 0 1 0 1 25 1 5 1 75 1 0 1 25 1 75 1 25 1 For applications driven by single cylinder engines refer to factory for other service factors 2 Rotary pump applications are considered as uniform loads 3 Use of belt or chain type drives to either reducer input or output shaft is not recommended Uniform Moderate Shock Heavy Shock Uniform Moderate Shock Heavy Shock Hydraulic Motor Multi Cylinder Internal Combustion Engine 1 5 2 0 A Size Helical Reducer Horsepower Table Part No Ratio 3 551 049 224 2 24 1 3 551 050 276 2 76 1 3 551 051 343 3 43 1 3 551 052 417 4 17 1 me ae SHAFT LOW SPEED SHAFT RPM INPUT RPM 1750 MAXIMUM REDUCER HP LOW SPEED SHAFT RPM 1450 MAXIMUM REDUCER HP LOW SPEED SHAFT RPM 1150 MAXIMUM REDUCER HP LOW SPEED SHAFT RPM 950 1 For input s
16. tock may be used to hold this alignment until the mounting bracket is securely bolted to the base plate It may be necessary to shim the bracket to the extact center height of the pump or driven shaft For additional information on coupling alignment refer to Engineering Service Bulletin ESB 61 USE STRAIGHT EDGE THESE SURFACES MUST BE PARALLEL m f CHECK WIDTH BETWEEN THESE SURFACES WITH INSIDE CALIPERS TO BE CERTAIN THE FACES ARE EQUAL DISTANCE APART AND PARALLEL FIGURE 6 COUPLING ALIGNMENT 5 Rotate the reducer in the banana slots of the bracket until the high speed coupling half is at the exact center height of the motor coupling half 6 Securely tighten the reducer to the bracket 7 Align the high speed shaft coupling and fasten the motor securely to base plate CAUTION DO NOT EXCEED RECOMMENDED MAXIMUM HORSEPOWER SEE CATALOG SPECIFICATION SHEET DO NOT OPERATE BEFORE ADDING LUBRICANT OPERATION After the first few hours of operation inspect reducer for leaks If leakage between gear case and cover cannot be stopped by tightening of nuts or capscrews the gasket should be replaced Leakage around either shaft indicates a damaged lip seal which should be replaced The operating temperature on the outside of the reducer case after a few hours operation should not be more than approximately 75 F higher than surrounding air temperature The oil within the Reducer should never exceed 200 F
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