BLACKMER CRL8A Manual

BLACKMER POWER PUMPS 960253
INSTRUCTIONS NO. 701-D00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS
MODELS: CRL8A
Section
Effective
Replaces
701
Mar 2016
Jan 2014
PUMP DATA
Technical Data.......................................................2
Initial Pump Start Up Information...........................2
INSTALLATION
Pre-Installation Cleaning........................................3
Location and Piping...............................................3
Pump Mounting......................................................3
Coupling Alignment................................................4
Pump Rotation.......................................................4
To Change Pump Rotation....................................4
Check Valves.........................................................4
OPERATION
Pre-Start Up Check List.........................................5
Start Up Procedures..............................................5
Running the Pump in Reverse Rotation ................5
Flushing the Pump.................................................6
Relief Valve Setting and Adjustment .....................6
MAINTENANCE
Torque Table .........................................................7
Scheduled Maintenance........................................7
Strainers ..........................................................7
Lubrication.......................................................7
Pump Disassembly................................................8
Seal/Bearing Replacement....................................8
Complete Pump Disassembly..............................10
Pump Assembly...................................................11
TROUBLE SHOOTING .................................................14
Numbers in parentheses following individual parts
indicate reference numbers on the Blackmer CRL8A
Parts List 701-D01.
Blackmer pump manuals and parts lists may be obtained
from Blackmer's website (www.blackmer.com) or by
contacting Blackmer Customer Service.
SAFETY DATA
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 Power Pumps 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.
This manual is intended to assist in the installation and
operation of Blackmer Power pumps, and MUST be kept
with the pump.
Pump 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 the
pump.
Maintain ALL system and pump operation and hazard
warning decals.

701-D00 page 2/16
SAFETY DATA
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Hazardous pressure
can cause personal
injury or property
damage
Hazardous voltage.
Can shock, burn or
cause death.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Hazardous
machinery can
cause serious
personal injury.
Do not operate
without guard
in place
If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
performing service or maintenance
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause serious
personal injury or property damage.
Hazardous or toxic
fluids can cause
serious injury.
Hazardous pressure
can cause serious
personal injury or
property damage
Always use a lifting device capable of
supporting the full weight of the pump
assemblies.
Failure to set the vehicle emergency
brake and chock wheels before
performing service can cause severe
personal injury or property damage
Heavy assemblies
can cause personal
injury or porperty
damage.
Hazardous
machinery can
cause serious
personal injury.
PUMP DATA
PUMP IDENTIFICATION
A pump Identification tag, containing the pump serial number, I.D. number, and model designation, is attached to each pump. It is
recommended that the data from this tag be recorded and filed for future reference. If replacement parts are needed, or if
information pertaining to the pump is required, this data must be furnished to a Blackmer representative.
TECHNICAL DATA *
CRL8A
Maximum Pump Speed 350 RPM
Maximum Operating Temperature 250°F (121°C)
Minimum Operating Temperature -30°F (-34°C)
Maximum Differential Pressure 100 psi (6.8 Bar)
Maximum Working Pressure 400 psi (27.5 Bar)
* Technical Data is for standard materials of construction.
Consult Blackmer Material Specs for optional materials of
construction.
INITIAL PUMP START UP INFORMATION
Model No.______________________________________
Serial No. _____________________________________
ID No. _________________________________________
Date of Installation: _____________________________
Inlet Gauge Reading: ____________________________
Discharge Gauge Reading: _______________________
Flow Rate: _____________________________________

701-D00 page 3/16
INSTALLATION
NOTICE:
Blackmer power pumps must only be installed in
systems designed by qualified engineering personnel.
System design must conform with all applicable
regulations and codes and provide warning of all
system hazards.
Install, ground and wire to local and
National Electrical Code requirements.
Install an all-leg disconnect switch near
the unit motor.
Disconnect and lockout electrical power
before installation or service
Electrical supply MUST match motor
n
a
m
ep
l
ate
spec
ifi
cat
i
o
n
s
.
Hazardous voltage.
Can shock, burn or
cause death.
Motors equipped with thermal protection automatically
disconnect motor electrical circuit when overload exists.
Motor can start unexpectedly and without warning.
WELDED CONNECTIONS
NOTICE:
Pumps with welded connections contain three non-
metallic gaskets that may be damaged if welding is done
with these gaskets installed.
Prior to welding the piping, remove the gaskets from under
the inlet flange, outlet flange and relief valve cover.
Reinstall the inlet and outlet flanges. Weld the piping to the
the inlet and outlet flanges. After the welding is complete,
reinstall the gaskets, cover and flanges.
PRE-INSTALLATION CLEANING
NOTICE:
New pumps might contain residual test fluid and/or rust
inhibitor. If necessary, flush pump prior to use.
Foreign matter entering the pump WILL cause extensive
damage. The supply tank and intake piping MUST be
cleaned and flushed prior to pump installation and operation.
LOCATION AND PIPING
An improperly designed piping system or improper unit
installation WILL significantly reduce pump performance and
life. Blackmer recommends the following piping system
layout and unit installation.
1. To minimize intake losses, locate the pump as close as
possible to the source of supply.
2. Intake piping and fittings MUST be at least as large in
diameter as the pump intake connection. It should slope
downward to the pump, and should not contain any
upward loops.
3. Minimize the number of intake line fittings (valves,
elbows, etc.) and piping turns or bends. When used,
intake fittings must be located at least 5 - 10 pipe
diameters from the pump intake.
4. Install an intake strainer 5 - 10 pipe diameters from the
pump intake. The strainer should have a net open area
of at least four times the area of the intake pipe.
5. Strainers must be cleaned regularly to avoid pump
starvation.
6. Intake and discharge piping MUST be free of all leaks.
7. Expansion joints, placed at least 36" (0.9m) from the
pump, will compensate for expansion and contraction of
the pipes. Contact the flexible connector/hose
manufacturer for required maintenance/care and design
assistance in their use.
8. Install pressure gauges in the NPT ports provided in the
pump casing to check pump at start up.
9. ALL piping and fittings MUST be properly supported to
prevent any piping loads from being placed on the pump.
10. Check alignment of pipes to pump to avoid strains which
might later cause misalignment. See Figure 1. Unbolt
flanges or break union joints. Pipes should not spring
away or drop down. After pump has been in operation
for a week or two, completely recheck alignment.
Figure 1
11. The use of a 4” (100mm) vapor return line will speed
delivery by preventing pressure build up at the receiving
tank and pressure reduction in the supply tank.
12. Keeping the liquefied gas systems full of liquid, even
when idle, will keep the O-rings from changing shape,
shrinking or super cooling. Evaporation of liquefied gas
leaves an abrasive powder on the surface which can
cause wear to the pump, meter, and seals.
PUMP MOUNTING
Permanently mount the unit by securing the base plate with
adequately sized anchor bolts to a level concrete floor
following recommended industry standards. A solid
foundation will reduce system noise and vibration, and will
improve pump performance. Refer to ANSI/HI standards or a
suitable pump handbook for information on typical pump
mounting and foundations. Check coupling alignment after
pump and base assembly is secured to the foundation.
Figure 2 - Pipe Type Anchor Bolt Box
When installing units built on channel or structural steel type
bases, use care to avoid twisting the base out of shape when
anchor bolts are tightened. Shims should be used under the
edges of the base prior to tightening of the anchor bolts to
prevent distortion. See figure 2 for proper orientation

701-D00 page 4/16
INSTALLATION
COUPLING ALIGNMENT
The pump must be directly coupled to a gear and/or driver
with a flexible coupling. Verify coupling alignment after
installation of new or rebuilt pumps. Both angular and parallel
coupling alignment MUST be maintained between the pump,
gear, motor, etc. in accordance with manufacturer’s
instructions. See Figure 3.
Figure 3 – Alignment Check
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 should be less
than .005" (0.127 mm).
2. Angular alignment: Insert a feeler gauge between the
coupling halves. Check the spacing at 90° increments
around the coupling (four check points). Maximum
variation should not exceed .005" (125 microns). Some
laser alignment tools will check angular alignment as
well.
3. Replace the coupling guards after setting alignment.
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
PUMP ROTATION
To determine pump rotation:
If the intake port is on the right, with the drive end of the shaft
pointing towards the observer, the pump is right-hand, or
CLOCKWISE rotation.
If the intake is on the left, with the drive end of the shaft
pointing towards the observer, the pump is left-hand, or
COUNTERCLOCKWISE rotation.
NOTICE:
Confirm correct pump rotation by checking the pump
rotation arrows respective to pump driver rotation.
TO CHANGE PUMP ROTATION
To change pump rotation the pump must be disassembled
and the liner (41), vanes (14) and pump mounted relief valve
(if equipped) must be reversed. Refer to “Pump
Disassembly” and “Pump Assembly” sections of this manual
for parts removal and replacement instructions.
Figure 4 – Reversing the Relief Valve
CHECK VALVES
If a check valve is used, install it at the pump discharge. The
use of check valves or foot valves in the supply tank is not
recommended with self-priming, positive displacement
pumps.
If the possibility of liquid backflow exists when the pump is off,
a check valve in the pump discharge piping is recommended
because the pump can motor in the reverse rotation and
create undue stress on all attached components. Never start
a pump when it is rotating in the reverse rotation as the
added starting torque can damage the pump and related
equipment.
INTERNAL PUMP RELIEF VALVE AND
EXTERNAL BYPASS VALVE
NOTICE:
The optional pump internal relief valve is designed to
protect the pump from excessive pressure and must not
be used as a system pressure control valve.
For ALL liquefied gas applications, install an external bypass
valve, and any necessary piping, back to the tank. DO NOT
pipe the bypass valve back to the intake line. The setting on
the external bypass valve must be at least 25 psi (1.7 bar)
lower than the pump internal relief valve setting. The valve
and piping must be of adequate size to accommodate the full
flow from the pump when the discharge line is closed.

701-D00 page 5/16
OPERATION
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage
Hazardous pressure
can cause serious
personal injury or
property damage
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause serious
personal injury or property damage.
Hazardous pressure
can cause serious
personal injury or
property damage
Pumps operating against a closed
valve can cause system failure,
personal injury and property damage
Hazardous
pressure can
cause personal
injury or property
da
m
age
PRE-STARTUP CHECK LIST
1. Check the alignment of the pipes to the pump. Pipes
must be supported so that they do not spring away or
drop down when pump flanges or union joints are
disconnected.
2. Verify proper coupling alignment.
3. Install pressure gauges in the 1/4" NPT intake and
discharge ports located on the pump casing to check
pump performance after start-up.
4. Ensure all valves and fittings in piping system are in the
start-up or operating positions.
5. Check the wiring of the pump motor and jog the pump
motor to verify proper pump rotation.
STARTUP PROCEDURES
NOTICE:
Consult the "General Pump Troubleshooting" section of
this manual if difficulties during start up are experienced.
1. SLOWLY build pressure in the pump.
2. Start the motor. Priming should occur within one minute.
3. Check the inlet and discharge pressure gauges to ensure
the system is operating within expected parameters.
Record the gauge readings in the "Initial Start Up
Information" section of this manual.
4. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
5. Check the flow rate to ensure the pump is operating
within the expected parameters. Record flow rate in the
“Initial Start Up Information” section.
6. Check the pressure setting of the relief valve by
momentarily closing a valve in the discharge line and
reading the pressure gauge. This pressure should be 10
-20 psi (0.7-1.4 bar) higher than the maximum system
operating pressure, or the external system pressure
control valve setting (if equipped). DO NOT operate the
pump against a closed discharge valve for more than
15 seconds. If adjustments are needed, refer to the
"Relief Valve Setting and Adjustment" section of this
manual.
7. The external bypass valve must always be set at least 25
PSI (1.7 bar) lower than the internal pump relief valve.
NOTE: The normal operating pressure must be at least 5
- 15 PSI (0.3 -1.0 bar) less than the external bypass
valve setting. Pump speeds which result in higher
pressures (nearing the valve setting) forces the liquid to
recirculate, creating excessive wear on the pump and
equipment.
Incorrect settings of the pressure
relief valve can cause pump
component failure, personal injury,
and property damage.
Hazardous pressure
can cause personal
injury or property
damage
RUNNING THE PUMP IN REVERSE
ROTATION NOTICE:
Pump should be operated in reverse rotation for no more
than 10 minutes and only when a separate pressure relief
valve is installed to protect the pump from excessive
pressure.
It may be desirable to run the pump in reverse rotation for
system maintenance. The pump will operate satisfactorily in
reverse rotation for a LIMITED time, at a reduced
performance level.

701-D00 page 6/16
OPERATION
FLUSHING THE PUMP
NOTICE:
If flushing fluid is to be left in the pump for an extended
time, it must be a lubricating, non-corrosive fluid. If a
corrosive or non-lubricating fluid is used, it must be
flushed from the pump immediately.
1. To flush the pump, run the pump with the discharge
valve open and the intake valve closed. Bleed air into
the pump through the intake gauge plug hole or through
a larger auxiliary fitting in the intake piping. Pump air for
30 second intervals to clean out most of the pumpage.
2. Run a system compatible flushing fluid through the pump
for one minute to clear out the remainder of the original
pumpage.
3. To remove the flushing fluid, follow step 1 above.
NOTICE:
After flushing the pump some residual fluid will remain in
the pump and piping. NOTICE:
Properly dispose of all waste fluids in accordance with
the appropriate codes and regulations.
RELIEF VALVE SETTING AND
ADJUSTMENT
Incorrect settings of the pressure
relief valve can cause pump
component failure, personal injury,
and property damage.
Hazardous pressure can
cause personal injury or
property damage
Relief valve cap is exposed to
pumpage and will contain some fluid
Hazardous or toxic
fluids can cause
serious injury.
The factory relief valve pressure setting is marked on a metal
tag attached to the valve cover. The relief valve must be set
at least 10 - 20 psi (0.7-1.4 bar) higher than the maximum
system operating pressure or the system pressure control
valve setting.
DO NOT remove the R /V Cap OR adjust the relief valve
pressure setting while the pump is in operation.
1. To INCREASE the pressure setting, remove the relief
valve cap, loosen the locknut, and turn the adjusting
screw inward, or clockwise. Replace the valve cap.
2. To DECREASE the pressure setting, remove the relief
valve cap, loosen the locknut, and turn the adjusting
screw outward, or counterclockwise. Replace the valve
cap.
Refer to the individual Blackmer pump parts lists for various
spring pressure ranges. Unless specified otherwise, pumps
are supplied from the factory with the relief valve adjusted to
the mid-point of the spring range.

701-D00 page 7/16
MAINTENANCE
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Hazardous voltage.
Can shock, burn or
cause death.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
shock, burns or death
Hazardous
machinery can
cause serious
personal injury.
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause serious
personal injury or property damage.
Systems with meters will still be
pressurized even after the hose is
emptied
Hazardous pressure
can cause serious
personal injury or
property damage
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
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.
Always use a lifting device capable of
supporting the full weight of the pump
assemblies.
Heavy assemblies
can cause personal
injury or porperty
damage.
NOTICE:
Maintenance shall be performed by qualified technicians
only, following the appropriate procedures and warnings
as presented in this manual.
TORQUE TABLE
Capscrew Torque Values
Head Hub Bearing
Cover
CRL8 178 lbs-ft.
(241 Nm) 50 lbs-ft. (68 Nm) 50 lbs-ft. (68 Nm)
SCHEDULED MAINTENANCE
STRAINERS
Strainers must be cleaned regularly to avoid pump starvation.
Schedule will depend upon the application and conditions.
LUBRICATION
NOTICE:
To avoid possible entanglement in moving parts do not
lubricate pump bearings, gear reducer or any other parts
while the pump is running.
NOTICE:
If pumps are repainted in the field, ensure that the grease
relief fittings (76A) are functioning properly after
painting. Do NOT paint them closed. Remove any
excess paint from the fittings.
Ball bearings must be lubricated every three months at
minimum. More frequent lubrication may be required
depending on the application and operating conditions.
Recommended Grease:
Dow Corning® - MOLYKOTE 44
DuPont® - KRYTOX GPL 203
NOTICE:
Use ONLY recommended grease. Using petroleum based
grease or oil to lubricate seal O-rings WILL cause seal O-ring
damage and subsequent product leakage.
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
covers (27 and 27A).
2. SLOWLY apply grease with a hand gun until grease
begins to escape from the grease relief fitting port.
Discard excess grease in accordance with proper codes
and regulations.
3. Replace the grease relief fittings (76A).
DO NOT overgrease pump bearings. While it is normal
for some grease to escape from the grease tell-tale hole
after lubrication, excessive grease can cause mechanical
seal failure. The tell-tale hole is located in the head or
hub between the bearing and the seal.
Lubricate the ball bearings, and hydraulic motor
couplings (if equipped), every three months at a
minimum

701-D00 page 8/16
MAINTENANCE
PUMP DISASSEMBLY
NOTICE:
Follow all hazard warnings and instructions provided in
the “Maintenance” section of this manual.
Always use a lifting device capable of
supporting the full weight of the pump
assemblies.
Heavy assemblies can
cause personal injury
or porperty damage.
NOTICE:
Use a hoist and appropriate sling or lifting lugs attached
to the baseplate to lift the entire pump assembly.
Eyebolts attached to the pump, gearbox, or motor must
be used to lift that particular component only.
NOTICE:
Use a hoist and eyebolts installed in the threaded holes
located in the heads, discs, rotor and casing to lift the
heavy pump parts.
Note: If a seal, bearings or vanes are to be replaced, the
pump may be left in the upright (shaft horizontal)
position. If the rotor-shaft or liner is to be removed, the
pump will have to be placed on its side (shaft vertical) for
some operations.
CRL8 pumps are equipped with hubs (20C) which allow
for bearing (24) and seal (153) replacement without
disturbing the pump head bolts (21). This document
covers both the “Seal or Bearing only”
Disassembly/Reassembly and “Complete pump”
Disassembly/Reassembly
FOR SEAL AND/OR BEARING ONLY
REPLACEMENT
1. Flush the pump per instructions in this manual. Drain
and relieve pressure from the pump and system as
required. A 3/4" drain plug (29) is fitted in each head.
2. With the pump upright (shaft horizontal). Clean the
pump shaft thoroughly, making sure the shaft is free of
nicks and burrs. This will prevent damage to the
mechanical seal when the inboard hub or head assembly
is removed.
3. Remove the inboard bearing cover capscrews (28) and
slide the inboard bearing cover (27A) and gasket (26) off
the shaft. Discard the bearing cover gasket.
4. Removing the locknuts and lockwashers (24A and 24B):
a. Bend up the engaged lockwasher tang and rotate
the locknut counterclockwise to remove it from the
shaft
b. Slide the lockwasher off the shaft. Inspect the
lockwasher for damage and replace as required.
5. Move to the outboard side of the pump and remove the
outboard bearing cover capscrews (28) and slide the
outboard bearing cover (27) and gasket (26) off the shaft.
Discard the bearing cover gasket.
6. Bend up the engaged lockwasher tang and tighten the
locknut (24A) on outboard end until shaft cannot be
rotated by hand. This will ensure proper rotor/shaft (13)
alignment during reassembly.
7. Return to the inboard side of the pump and wrap the
shaft threads with tape to ensure that grease seal (104A)
is not damaged upon hub removal.
8. Remove the capscrews (21A) from the inboard hub
(20C) and slide the hub assembly off the shaft. The
bearing (24), grease seal carrier assembly (104B, 104A
and 104C), stationary seat (153B) and stationary O-ring
(153D) of the mechanical seal will come off with the hub.
a. Pull the bearing (24) and grease seal carrier
assembly (104B, 104A and 104C) from the housing
in the hub.
b. If worn or damaged, remove the grease seal (104A)
from the carrier (104B).
c. To remove the mechanical seal stationary seat
(153B), remove the seal retaining screws and
washers (153Q, 153R). Gently push the backside of
the stationary seat from the seal recess. Place a
cloth under the seal to avoid damage. Be careful not
to contact the polished face of the seal during
removal. Remove and discard mechanical seal
stationary O-ring.
Figure 6 – Seal removal and Installation
9. Remove the remaining mechanical seal parts, including
the seal spring holder, springs, retaining ring, rotating O-
ring and face (153G, 153H, 153N, 153L, 153F) from the
shaft sleeve (154) by removing capscrews (153J).See
Figure 6. Take care to protect the carbon rotating face
from damage during disassembly. Remove and discard
rotating O-ring.
153GSealSpringHolder,
153JRetainingScrews(4)
154AShaftSleeve,
155RetainingScrews(2)

102-A00 page 9/16
MAINTENANCE
10. Inspect shaft sleeve (154A). If replacement is
necessary, remove capscrews (155), set aside. If
necessary, use seal mounting holes as jackscrew holes
to assist disassembly. See Figure 7 Discard stationary O-
ring (154B).
Figure 7 – Shaft sleeve removal and installation
11. To install new shaft sleeve (154A):
a. Lubricate inner O-ring (154B) using bearing
grease identified in lubrication section of this
manual. Install sleeve over shaft while aligning
mounting holes with corresponding threaded
holes in rotor. Sleeve should mount flush with
rotor
b. Place small amount of Loctite # 220 onto
capscrews (155), thread fully into rotor holes
through sleeve. Torque to 200 inlbf (22.6 Nm).
12. Lightly lubricate shaft sleeve surface with bearing grease
identified in lubrication section of this manual.
13. Install seal rotating assembly minus carbon rotating face
onto shaft sleeve. Take care to align mounting holes
with corresponding holes on shaft sleeve.
14. Place small amount of Loctite # 220 onto seal mounting
capscrews (153J). Install into corresponding threaded
holes on seal sleeve. Torque capscrews (153J) to 20
inlbf (2.25 Nm).
15. Lightly lubricate inner O-ring (153L) on carbon rotating
face using bearing grease identified in this manual. Take
care to keep seal face free from grease.
NOTICE:
Use ONLY recommended grease. Using petroleum
based grease or oil to lubricate seal O-rings WILL cause
seal O-ring damage and subsequent product leakage.
16. Install carbon rotating face (153F) and O-ring (153L) over
shaft sleeve (154A) while aligning drive notches in
carbon with drive pins in seal rotating assembly. (see
figure 8)
Figure 8 – Seal carbon alignment
17. Install a new stationary O-ring (153D) in the stationary
seat (153B). Clean the polished face with a clean tissue
and alcohol. Push the seat fully into the hub seal recess
with the polished face outward.
18. Apply small amount of Loctite # 220 to seal retaining
screws. Install seal retaining screws and washers
(153Q, 153R).
19. If removed, press the grease seal(104A) into the grease
seal carrier (104b) with the lips facing toward the
bearing. Place the grease seal carrier (104B) with new
O-ring (104C) into the hub (20C).
20. Hand pack the ball bearing (24) with grease. Refer to
the "Lubrication" section for the recommended grease.
21. Install the bearing into the recess of the hub (20C).
22. Temporarily attach the bearing cover (27) and gasket
(26) to hub and hand tighten capscrews (28).
23. Install new hub O-ring (72B) and carefully install the hub
assembly (20C) on head. Install and tighten hub
capscrews (21A) torquing as indicated in the “Torque
Table” in maintenance section of this manual
24. Remove bearing cover and install locknut and new
lockwasher until snug.
25. Loosen locknut on the outboard end of pump
26. Tighten locknut on near side
27. Repeat steps 7-24 for seal and/or bearing replacement of
opposite side of pump
28. Adjust locknuts per “Locknut Adjustment” instructions in
maintenance section of this manual
154AShaftSleeve,
155RetainingScrews(2)
153FRotatingSealFace
153GSealSpringHolder
153LO‐ring

102-A00 page 10/16
MAINTENANCE
VANE REPLACEMENT AND/OR
COMPLETE PUMP DISASSEMBLY
NOTICE:
Follow all hazard warnings and instructions provided in
the “Maintenance” section of this manual.
Always use a lifting device capable of
supporting the full weight of the pump
assemblies.
Heavy assemblies can
cause personal injury
or porperty damage.
NOTICE:
Use a hoist and appropriate sling or lifting lugs attached
to the baseplate to lift the entire pump assembly.
Eyebolts attached to the pump, gearbox, or motor must
be used to lift that particular component only.
NOTICE:
Use a hoist and eyebolts installed in the threaded holes
located in the heads, discs, rotor and casing to lift the
heavy pump parts.
Note: If a seal or vanes are to be replaced, the pump may
be left in the upright position. If the rotor-shaft or liner is
to be removed, the pump will have to be placed on its
side for some operations.
1. Flush the pump per instructions in this manual. Drain
and relieve pressure from the pump and system as
required. A 3/4" drain plug (29) is fitted in each head.
2. With the pump upright (shaft horizontal). Clean the
pump shaft thoroughly, making sure the shaft is free of
nicks and burrs. This will prevent damage to the
mechanical seal when the inboard hub or head assembly
is removed.
3. Remove the inboard bearing cover capscrews (28) and
slide the inboard bearing cover (27A) and gasket (26) off
the shaft. Discard the bearing cover gasket.
4. Removing the locknuts and lockwashers (24A and 24B):
a. Bend up the engaged lockwasher tang and rotate the
locknut counterclockwise to remove it from the shaft
b. Slide the lockwasher off the shaft. Inspect the
lockwasher for damage and replace as required.
5. Move to the outboard side of the pump and remove the
outboard bearing cover capscrews (28) and slide the
outboard bearing cover (27) and gasket (26) off the shaft.
Discard the bearing cover gasket.
6. Bend up the engaged lockwasher tang and tighten the
locknut (24A) on outboard end until shaft cannot be
rotated by hand. This will ensure proper rotor/shaft (13)
alignment during reassembly.
7. Return to the inboard side of the pump and wrap the
shaft threads with tape to ensure that grease seal (104A)
is not damaged upon hub removal.
8. Remove the capscrews (21A) from the inboard hub
(20C) and slide the hub assembly off the shaft. The
bearing (24), grease seal carrier assembly (104B, 104A
and 104C), stationary seat (153B) and stationary O-ring
(153D) of the mechanical seal will come off with the hub.
a. Pull the bearing (24) and grease seal carrier
assembly (104B, 104A and 104C) from the housing in
the hub.
b. If worn or damaged, remove the grease seal (104A)
from the carrier (104B).
c. To remove the mechanical seal stationary seat
(153B), remove the seal retaining screws and
washers (153Q, 153R). Gently push the backside of
the stationary seat from the seal recess. Place a cloth
under the seal to avoid damage. Be careful not to
contact the polished face of the seal during removal.
Remove and discard mechanical seal stationary O-
ring.
9. Remove the remaining mechanical seal parts, including
the seal spring holder, springs, retaining ring, rotating O-
ring and face (153G, 153H, 153N, 153L, 153F) from the
shaft sleeve (154) by removing capscrews (153J).See
Figure 6. Take care to protect the carbon rotating face
from damage during disassembly. Remove and discard
rotating O-ring.
10. Inspect shaft sleeve (154A). If replacement is
necessary, remove capscrews (155), set aside. If
necessary, use seal mounting holes as jackscrew holes
to assist disassembly. See Figure 7 Discard stationary O-
ring (154B).
11. To install new shaft sleeve (154A):
a. Lubricate inner O-ring (154B) using bearing grease
identified in lubrication section of this manual. Install
sleeve over shaft while aligning mounting holes with
corresponding threaded holes in rotor. Sleeve should
mount flush with rotor
b. Place small amount of Loctite # 220 onto capscrews
(155), thread fully into rotor holes through sleeve.
Torque to 200 inlbf (22.6 Nm).
12. Remove the head capscrews (21). If necessary, place
head capcrews in the two tapped holes near the outer
rim of the head and tighten until the head separates from
the casing. Use a hoist to remove the head from the
casing, being careful not to damage the shaft.
13. Remove the head O-ring (72) and disc (71). If needed,
threaded holes are provided in the disc to break it free.
14. Remove the top vane then rotate the shaft by hand to
bring the next vane to the top until all the vanes have
been removed. If the vanes are swollen or jammed in
their slots, the rotor-shaft must be removed.
15. If doing a vane-only replacement, skip to step 10 of
COMPLETE PUMP ASSEMBLY section of this manual
for pump reassembly
16. If full pump disassembly required, loosen and remove
outboard locknut (24A) and lockwasher (24B).
17. Set the pump on its side (shaft vertical) with the shaft
pointing up.
18. Attach a hoist to rotor-shaft, lift it out and set it aside.
The pushrods, and rotating portions of the seal will come
out with the rotor-shaft..
19. Set the pump upright (feet down).
20. Remove the outboard head components as described for
the inboard side in steps 7-12.
21. Attach a hoist to the liner. Use a block of wood or piece
of brass against the end of the liner, and drive the liner
out of the casing with a hammer by tapping the outside
diameter of the liner.

102-A00 page 11/16
MAINTENANCE
COMPLETE PUMP ASSEMBLY
Before reassembling the pump, inspect all component
parts for wear or damage, and replace as required. Wash
out the bearing/seal recess of the head and remove any
burrs or nicks from the rotor and shaft. Remove any
burrs from the liner.
NOTICE:
Use a hoist and eyebolts installed in the threaded holes
located in the heads, discs, rotor and casing to lift the
heavy pump parts.
Always use a lifting device capable of
supporting the full weight of the pump
assemblies.
Heavy assemblies can
cause personal injury
or porperty damage.
1. Set the pump casing upright (feet down).
2. The liner must be installed in the pump casing with the
word “INTAKE” cast on the liner toward the intake port of
the pump casing.
Align the keyway in the top of the liner with the pin in the
top of the casing.
Uniformly tap the outer edge of the liner with a rubber
mallet to fully insert into the casing.
3. Start assembly on the OUTBOARD non-driven side of
the pump:
For a CLOCKWISE rotation pump, the INTAKE port is to
the left.
For a COUNTERCLOCKWISE rotation pump, the
INTAKE port is to the right.
Loosely assemble the outboard disc (71) and head (20)
to the casing (12). The bearing, seal, O-rings, etc. will be
installed later.
4. Set the pump on its side with the outboard head DOWN.
Figure 5 – Vane Installation
5. Remove the vanes (14) and push rods (77) from the rotor
and shaft assembly. Inspect for wear and damage, and
replace as follows:
a. Insert the three push rods (77) into the rotor.
b. Using a hoist, lower the non-driven end of the rotor
and shaft into the open side of the pump casing,
being careful not to hit the disc with the shaft.
c. Insert the vanes into the rotor slots with the relief
grooves facing in the direction of pump rotation, and
with the rounded edges outward. See Figure 5.
6. If shaft sleeve (154A) previously removed, lubricate inner
O-ring (154B) using bearing grease identified in
lubrication section of this manual. Install sleeve over
shaft while aligning mounting holes with corresponding
threaded holes in rotor. Sleeve should mount flush with
rotor
7. Place small amount of Loctite # 220 onto capscrews
(155), thread fully into rotor holes through sleeve.
Torque to 200 inlbf (22.6 Nm).
8. Using a hoist, install the disc in the casing with the
smooth side of the disc towards the casing (seal cavity
outward) and the pressure relief hole 45 degrees
downward from the discharge side of the casing. The
seal cavity feedback hole should be exposed into inlet
area of pump. (SEE FIGURE 9). There exists a 2
nd
feedback hole in each disc which should be fully covered
by the liner near the seal point when properly oriented.
Figure 9 – Disc Orientation
9. Install a new head O-ring (72).
10. Using a hoist, carefully attach the head (20) to the casing
with the head drain hole towards the bottom of the pump.
Install and tighten the head capscrews (21).
11. Lightly lubricate shaft sleeve surface with bearing grease
identified in lubrication section of this manual.
12. Install seal rotating assembly minus carbon rotating face
onto shaft sleeve. Take care to align mounting holes
with corresponding holes on shaft sleeve.

102-A00 page 12/16
MAINTENANCE
13. Place small amount of Loctite # 220 onto seal mounting
capscrews (153J). Install into corresponding threaded
holes on seal sleeve. Torque capscrews to 20 inlbf
(2.25 Nm).
14. Lightly lubricate inner O-ring (153L) on carbon rotating
face using bearing grease identified in this manual. Take
care to keep seal face free from grease.
NOTICE:
Use ONLY recommended grease. Using petroleum
based grease or oil to lubricate seal O-rings WILL cause
seal O-ring damage and subsequent product leakage.
15. Install carbon rotating face and O-ring over shaft while
aligning drive notches with drive pins in seal rotating
assembly. (see figure 8)
16. Install a new stationary O-ring (153D) in the stationary
seat (153B). Clean the polished face with a clean tissue
and alcohol. Push the seat fully into the seal recess with
the polished face outward.
17. Apply small amount of Loctite #220 to seal retaining
screws. Install seal retaining screws and washers
(153Q, 153R).
18. If removed, press the grease seal(104A) into the grease
seal carrier (104b) with the lips facing toward the
bearing. Place the grease seal carrier (104B) with new
O-ring (104C) into the hub (20C).
19. Hand pack the ball bearing (24) with grease. Refer to
the "Lubrication" section for the recommended grease.
20. Install the bearing into the recess of the hub (20C).
21. Temporarily attach the bearing cover (27) and gasket
(26) to hub and hand tighten capscrews (28).
22. Install new hub O-ring (72B) and carefully install the hub
assembly (20C) on head. Install and tighten hub
capscrews (21A) torquing as indicated in the “Torque
Table”.
23. Remove the bearing cover and loosely install the bearing
locknut and lockwasher (24A, 24B). Snug the locknut on
the outboard head to help square the rotor with the head.
DO NOT overtighten the nut.
24. Set the pump upright.
25. Remove the outboard head and disc temporarily
attached earlier.
26. Complete assembly on the OUTBOARD side of the
pump as instructed for the inboard side in steps 10-24,
leaving the head capscrews loosely tightened.
27. Loosen the bearing locknut on the outboard head and
the rotate the shaft to test for binding or tight spots. If the
rotor does not turn freely, lightly tap the rims of the heads
with a soft faced mallet until the correct position is found.
Retighten all head capscrews, torquing to the
specifications indicated in the “Torque Table”.

102-A00 page 13/16
MAINTENANCE:
28. LOCKNUT ADJUSTMENT
It is important that the bearing locknuts (24A) and
lockwashers (24B) be installed and adjusted properly.
Overtightened locknuts can cause bearing failure or a
broken lockwasher tang. Loose locknuts will allow the
rotor to shift against the discs, causing wear. See Figure
10.
a. On both ends of the pump shaft, install a lockwasher
(24B) with the tangs facing outward, followed by a
locknut (24A) with the tapered end inward. Ensure
the inner tang "A" of the lockwasher is located in the
slot in the shaft threads, bending it slightly, if
necessary.
Figure 10 Locknut Adjustment
b. Tighten both locknuts to ensure that the bearings
are bottomed in the head recess. DO NOT
overtighten and bend or shear the lockwasher inner
tang.
c. Loosen both locknuts one complete turn.
d. Tighten one locknut until a slight rotor drag is felt
when turning the shaft by hand.
e. Back off the nut the width of one lockwasher tang
"B". Secure the nut by bending the closest aligned
lockwasher tang into the slot in the locknut. The
pump should turn freely when rotated by hand.
f. Tighten the opposite locknut by hand until it is snug
against the bearing. Then, using a spanner wrench,
tighten the nut the width of one lockwasher tang.
Tighten just past the desired tang, then back off the
nut to align the tang with the locknut slot. Secure
the nut by bending the aligned lockwasher tang into
the slot in the locknut. The pump should continue to
turn freely when rotated by hand.
29. Inspect the grease seal (104) for wear or damage and
replace as required. Grease the outside diameter of the
grease seal and push it into the inboard bearing cover
(27A) with the lip of the seal outward.
30. Attach a new bearing cover gasket (26) and the inboard
bearing cover (27A) to the inboard side of the pump.
Install the outboard bearing cover (27) and a new gasket
to the outboard side of the pump. Make sure the grease
fittings (76) on the bearing covers are accessible. Install
and torque the bearing cover capscrews (28) as
indicated in the “Torque Table”.
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard in
place.
31. RELIEF VALVE ASSEMBLY (if equipped)
a. Insert the valve (9) into the relief valve body(6) with
the fluted end inward.
b. Install the relief valve spring (8), spring guide (7) and
guide rod (45) against the valve.
c. Attach a new relief valve gasket (10) and the valve
cover (4) on the cylinder.
d. Screw the relief valve adjusting screw (2) into the
valve cover until it makes contact with the spring
guide (7).
e. Install the relief valve cap (1) and gasket (88) after
the relief valve has been precisely adjusted.
NOTICE:
The relief valve setting MUST be tested and
adjusted more precisely before putting the pump
into service. Refer to "Relief Valve Setting and
Adjustment"
32. Reinstall coupling, shaft key, and coupling guards.
33. Refer to “Pre-Start Up Check List” and “Start Up
Procedures” sections of this manual prior to pump
operation.

701-D00 page 14/16
TROUBLESHOOTING
NOTICE:
Maintenance shall be performed by qualified technicians only,
following the appropriate procedures and warnings as presented in this manual.
SYMPTOM PROBABLE CAUSE
Pump Not Priming
1. Pump not wetted.
2. Worn vanes.
3. Suction valve closed.
4. Internal control valve closed.
5. Strainer clogged.
6. Suction line or valves clogged or too restrictive.
7. Broken drive train.
8. Pump vapor-locked.
9. Pump speed too low for priming.
10. Relief valve partially open, worn or not seating properly.
11. Vanes installed incorrectly (see "Vane Replacement").
12. Incorrect Rotation
Reduced Capacity
1. Pump speed too low.
2. Suction valves not fully open.
3. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows &
fittings, clogged strainer, etc.).
4. Damaged or worn parts (vanes, discs, liner or rotor).
5. Excessive restriction in discharge line causing partial flow through the relief valve.
6. Relief Valve worn, set too low, or not seating properly.
7. External Bypass Valve set too low.
8. Operating without a vapor return line.
9. Vanes installed incorrectly (see "Vane Replacement").
10. Liner installed backwards.
Noise
1. Excessive pressure drop in suction line due to:)
a. Undersized or restricted fittings in the suction line.
b. Pump speed too fast.
c. Pump too far from fluid source.
2. Running the pump for extended periods with a closed discharge line.
3. Pump not securely mounted.
4. Misalignment of pump, reducer or motor.
5. Bearings worn or damaged.
6. Vibration from improperly anchored piping.
7. Bent shaft, or drive coupling misaligned.
8. Insufficient oil in the gear reducer.
9. Excessively worn rotor.
10. Malfunctioning valve in the system.
11. Relief valve setting too low.
12. Liner installed backwards.
13. Damaged vanes (see following category).

701-D00 page 15/16
TROUBLESHOOTING
NOTICE:
Maintenance shall be performed by qualified technicians only,
following the appropriate procedures and warnings as presented in this manual.
SYMPTOM PROBABLE CAUSE
Damaged Vanes
1. Foreign objects entering the pump.
2. Running the pump dry for extended periods of time.
3. Cavitation.
4. Incompatibility with the liquids pumped.
5. Excessive heat.
6. Worn or bent push rods, or worn push rod holes.
7. Hydraulic hammer - pressure spikes.
8. Vanes installed incorrectly (see"Vane Replacement").
Broken Shaft
1. Foreign objects entering the pump.
2. Relief valve not opening.
3. Hydraulic hammer - pressure spikes.
4. Pump/driver, driveline/drive shaft misalignment.
5. Excessively worn vanes or vane slots.
SEAL LEAKAGE
1. O-rings not compatible with the liquids pumped.
2. O-rings nicked, cut or twisted.
3. Shaft at seal area damaged, worn or dirty.
4. Ball bearings overgreased.
5. Excessive cavitation.
6. Mechanical seal faces cracked, scratched, pitted or dirty.
MOTOR OVERLOAD
1. Horsepower of motor not sufficient for application
2. Improper wire size / wiring and/or voltage to motor.
3. Misalignment in pump drive system.
4. Excessive viscosity, pressure or speed.
5. Bearing locknuts adjusted improperly.
6. Faulty or worn bearings.
7. Rotor rubbing against head or cylinder.
8. Dirty mechanical seal faces.

701-D00 page 16/16
1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A.
Telephone: [phone] • Fax: [phone]