BLACKMER HXL6G Manual

BLACKMER POWER PUMPS 960229
INSTRUCTIONS NO. 102
-
A00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS
MODELS: HXL6G, HXL8G, HXLJ8G, HXL10E
Section
Effective
Replaces
102
Jun 2020
Jan 2014
TABLE OF CONTENTS
Page
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
Manual Bypass Valves ............................................... 4
OPERATION
Pre-Start Up Check List .............................................. 5
Start Up Procedures ................................................... 5
Running the Pump in Reverse Rotation ..................... 5
Flushing the Pump ..................................................... 6
Pump Relief Valve ...................................................... 6
Relief Valve Setting and Adjustment .......................... 6
MAINTENANCE
Torque Table .............................................................. 7
Scheduled Maintenance ............................................. 7
Strainers ............................................................... 7
Lubrication ............................................................ 7
Vane Replacement ..................................................... 8
Pump Disassembly (HXL6 and HXLJ8) ...................... 9
Pump Assembly (HXL6 and HXLJ8) ......................... 9
Pump Disassembly (HXL8 and HXL10) ................... 11
Pump Assembly (HXL8 and HXL10) ....................... 12
TROUBLE SHOOTING....................................................... 14
Numbers in parentheses following individual parts indicate
reference numbers on the Blackmer Parts List for the pump
being serviced.
PUMP PARTS LISTS
HXL6 HXL8, HXLJ8 HXL10
102-A01 102-A02 102-A04
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.

102-A00 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.
Heavy assemblies
can cause personal
injury or porperty
damage.
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 *
HXL6G HXL8G
HXLJ8G HXL10E
Maximum Pump
Speed 350 RPM 350 RPM 230 RPM
Maximum Operating
Temperature
300°F
(149°C)
300°F
(149°C)
300°F
(149°C)
Maximum Differential
Pressure
125 psi
(8.6 Bar)
150 psi
(10.3 Bar)
150 psi
(10.3 Bar)
Maximum Working
Pressure
150 psi
(10.3 Bar)
250 psi
(17.2 Bar)
250 psi
(17.2 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: _____________________________________

102-A00 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
nameplate specifications.
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.
PRE-INSTALLATION CLEANING
NOTICE:
New pumps contain residual test fluid and 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.
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. For viscosities less than 1000 SSU, the
strainer should have a net open area of at least four
times the area of the intake pipe. For viscosities greater
than1000 SSU, consult the strainer manufacturer
instructions.
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. When pumping liquids at elevated temperature,
provisions should be made to compensate for expansion
and contraction of the pipes, especially when long pipe
lines are necessary. Steel pipe expands approximately
3/4” (1.9 cm) per 100 feet (30.49 m) per 100°F (37.8°C)
rise in temperature.
PUMP MOUNTING
It is recommended the unit be permanently mounted 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.

102-A00 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.
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
The vanes (14) must be reversed so that the relief grooves
face in the direction of rotation. On HXL10, HXL8 and HXLJ8
models, reverse the liner (41). If equipped with a pump
mounted relief valve, it must also be reversed (see Figure 4).
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.
MANUAL BYPASS VALVES
A bypass line from the pump discharge to the pump suction
with a manual shut-off valve is recommended when handling
volatile or viscous liquids at a high lift, or when delivering to
piping too small to take the full flow from the pump.
The following size of manual bypass valve and recirculating
lines are normally recommended:
6" pump
8" pump
10" pump
2" valve and piping
3" valve and piping
4" valve and piping
When handling very viscous liquids, excessive pressures may
develop when starting the system. To avoid possible damage
to the pump, open the manual bypass valve before starting.
After the pressure stabilizes and the pump is running
smoothly, close the valve slowly to increase the flow through
the system until maximum acceptable system performance is
attained.
As heavy liquids with “light ends” are heated to a higher
temperature to lower the viscosity, the amount of volatile
product given off is increased. The resulting cavitation may
cause the pump to become noisy and begin vibrating. By
cracking the manual bypass valve open and permitting some
of the liquid to recirculate back to the pump inlet pipe or to the
supply tank, the noise and vibration can be reduced to an
acceptable level. If the pump noise and vibration cannot be
controlled with the manual bypass valve, look for other
causes of noise in the “Troubleshooting” section of this
manual.

102-A00 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
damage
PRE-START UP CHECK LIST
1. Check the alignment of the pipes to the pump. Pipes
should 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.
START UP PROCEDURES
NOTICE:
Consult the "General Pump Troubleshooting" section of
this manual if difficulties during start up are experienced.
1. Start the motor. Priming should occur within one minute.
2. 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.
3. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
4. Check the flow rate to ensure the pump is operating
within the expected parameters. Record flow rate in the
“Initial Start Up Information” section.
5. 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.
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.

102-A00 page 6/16
OPERATION
HEATING HEADS / JACKETS (HXLJ8G)
NOTICE:
Maximum recommended heating jacket steam pressure
is 150 PSI (10.3 bar).
Jacketed heads are recommended for heating highly viscous
liquids, or to “thaw out” liquids that have congealed in the
pumping chamber and packing area.
Hot oil or steam can be circulated through the jacketed heads
by 1” NPT connections above and below the shaft.
Pumps fitted with heating devices have
hot surfaces that can cause serious
personal injury.
Extreme heat can
cause injury or
property damage.
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.
PUMP RELIEF VALVE
NOTICE:
The pump internal relief valve is designed to protect the
pump from excessive pressure and must not be used as
a system pressure control valve.
HXL pump models are offered with an optional relief valve
assembly bolted onto the pump casing. Pumping volatile
liquids under suction lift may cause cavitation. Partial closing
of the discharge valve WILL result in internal relief valve
chatter and is NOT recommended. For these applications,
Install an external system pressure control valve, and any
necessary bypass piping, back to the storage tank.
A system pressure control valve is also recommended when
operating for extended periods (more than 15 seconds)
against a closed discharge valve.
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.

102-A00 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.
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
HXL6 100 lbs-ft.
(136 Nm) --- 50 lbs-ft. (68 Nm)
HXL8 178 lbs-ft.
(241 Nm)
50 lbs-ft.
(68 Nm)
50 lbs-ft.
(68 Nm)
HXLJ8 178 lbs-ft.
(241 Nm) --- 50 lbs-ft. (68 Nm)
HXL10 178 lbs-ft.
(241 Nm)
100 lbs-ft.
(136 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:
Models: HXL6, HXL8 and HXL10
Mobil® - Mobilgrease XHP222,
Exxon® - RONNEX MP Grease,
or equivalent.
Model: HXLJ8
Exxon® - Polyres, or Mobil® - MOBIL Poly 372, or
equivalent Polyurea grease.
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

102-A00 page 8/16
MAINTENANCE
VANE REPLACEMENT
NOTICE:
Maintenance shall be performed by qualified technicians
only, following the appropriate procedures and warnings
as presented in manual.
Figure 5 – Vane Installation
1. Vanes may be replaced with the pump in the upright
position.
2. Flush the pump per instructions in this manual. Drain
and relieve pressure from the pump and system as
required.
3. Remove the head assembly from the outboard
(nondriven) side of the pump according to steps 4 - 8 in
the "Pump Disassembly" section of this manual.
4. Turn the shaft by hand until a vane comes to the top
(12 o'clock) position of the rotor. Remove the vane.
5. Install a new vane, ensuring that the rounded edge is
UP, and the relief grooves are facing towards the
direction of rotation. See Figure 5.
6. Repeat steps 3 and 4 until all vanes have been replaced.
This method of vane installation ensures the push rods
do not fall out of their rotor slots.
7. Reassemble the pump according to the "Pump
Assembly." section of this manual.

102-A00 page 9/16
MAINTENANCE: HXL6 and HXLJ8 MODELS
PUMP DISASSEMBLY – HXL6 and HXLJ8
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. Relieve
pressure from the pump and system and drain as
required.
HXLJ8: A 3/4" plug (29) is fitted in each head to allow
draining the coolant.
2. Set the pump upright. 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 head assembly is removed.
3. HXL6: 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.
HXL8J: Remove the inboard bearing cover capscrews
(28) , head capscrews (21), and the head stud nuts
(21C). Slide the inboard bearing cover (27A) and gasket
(26) off the shaft. Discard the bearing cover gasket.
4. 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.
The bearing, stationary seat and stationary O-ring will
come off with the head assembly.
HXLJ8: Remove the two head studs.
5. Remove the head O-ring (72) and disc (71) . If needed,
threaded holes are provided in the disc to break it free.
6. 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 as described
below.
7. Set the pump on its side with the shaft pointing up.
8. Attach a hoist to the rotor-shaft, lift it out and set aside.
The pushrods, and rotating portions of the seal will come
out with the rotor-shaft.
9. Set the pump upright.
10. Remove the outboard head components as described for
the inboard side in steps 3 – 5.
11. 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.
PUMP ASSEMBLY – HXL6 and HXLJ8
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.
2. Align the keyway in the top of the liner with the pin in the
top of the casing.
HXL6: Liner is symmetrical and can be installed in either
direction.
HXLJ8: 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.
a. 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), head (20) (and
bearing cover (27) on the HXLJ8) 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.

102-A00 page 10/16
MAINTENANCE: HXL6 and HXLJ8 MODELS
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.
6. 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. 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 towards the bottom of the casing (6
o’clock position).
7. Install a new head O-ring (72).
8. The mechanical seal and bearing must be installed
before attaching head to pump casing.
a. Apply a small amount of motor oil on the shaft
between the shaft threads and the rotor. Wrap tape
over the shaft threads to prevent damage to
mechanical seal O-rings.
b. Slide the seal jacket assembly over the shaft and
into the seal cavity with the drive tangs of the jacket
towards the rotor. Rotate the jacket assembly to
engage the drive tangs in the rotor slots.
c. Install a new rotating O-ring (153L) in the rotating
seal face (153F). Align and insert the rotating
assembly into the the seal jacket with the polished
face outward. Clean the polished face with a clean
tissue and alcohol. Bronze seal faces should be
oiled during installation, but other seal faces must be
kept clean and dry. Note: Carbon/PTFE rotating
seal face (153M) is installed as a one-piece
assembly.
d. Apply a small amount of motor oil in the seal recess
of the head
e. Install a new stationary O-ring (153D) in the
stationary seat (153B). Clean the polished face with
a clean tissue and alcohol, then push the seat fully
into the seal recess with the polished face outward.
f. Hand pack the ball bearing (24) with grease. Refer
to the "Lubrication" section for the recommended
grease. Install the bearing into the recess of the
head.
g. 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.
h. Attach bearing cover (27A) and gasket (26) to head.
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”.
i. Using a hoist, carefully attach the head to the
casing. Use care not to damage seal components
during installation. Install and HAND-TIGHTEN the
head capscrews (21).
j. HXLJ8: Install head studs (21B) and hand-tighten
the nuts (21C).
9. Set the pump upright.
10. Remove the outboard head and disc temporarily
attached earlier.
11. Complete assembly on the OUTBOARD side of the
pump as instructed for the inboard side in steps 6 – 8.
12. Ensure that the pump turns freely. If binding occurs, tap
the rim of the head with a mallet until binding is relieved
and shaft turns freely. Torque head capscrews as
indicated in the “Torque Table” (and studnuts on the
HXLJ8) and recheck for free turning.
13. 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"
14. Reinstall coupling, shaft key, and coupling guards.
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard in
place.
15. Refer to “Pre-Start Up Check List” and “Start Up
Procedures” sections of this manual prior to pump
operation.

102-A00 page 11/16
MAINTENANCE: HXL8 and HXL10 MODELS
PUMP DISASSEMBLY – HXL8 and HXL10
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. 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. 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.
5. 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.
c. Repeat steps a and b on the opposite shaft end.
6. Remove the capscrews from the hub (21A) and slide the
hub assembly off the shaft. The bearing, stationary seat
and stationary O-ring of the mechanical seal (153B,
153D) will come off with the hub.
a. Pull the bearing (24) from the housing in the hub.
b. To remove the mechanical seal stationary seat
(153B), remove the seal retaining screws and
washers (153Q, 153R, 153S) 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.
c. Remove the remaining mechanical seal parts,
including the seal jacket and rotating face (153F,
153L, 153G) from the shaft. A piece of stiff wire with
a hook on the end may be used to withdraw the seal
components from the shaft. Remove and discard
rotating O-ring
7. 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.
8. HXL8: Remove the head O-ring (72) and disc (71). If
needed, threaded holes are provided in the disc to break
it free.
HXL10: The head O-ring (72) and disc (71) will come off
with the head assembly. Remove the counter sunk set
screws and lockwashers (71A & 71B) to release the disc
from the head. Install an eyebolt in the disc and use a
hoist to remove the disc from the head.
9. 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.
10. Set the pump on its side with the shaft pointing up.
11. 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..
12. Set the pump upright.
13. Remove the outboard head components as described fro
the inboard side in steps 6 - 8.
14. HXL10: Remove the four (4) liner retaining screws and
washers (127, 127A) located between the relief valve
ports.
15. 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 12/16
MAINTENANCE: HXL8 and HXL10 MODELS
PUMP ASSEMBLY – HXL8 and HXL10
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.
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.
HXL8: Align the keyway in the top of the liner with the pin
in the top of the casing.
HXL10: Align rib at top of the liner between the liner
retainer screw holes.
Uniformly tap the outer edge of the liner with a rubber
mallet to fully insert into the casing.
HXL10: Install four liner retainer screws and seals (127,
127A)
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.
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. HXL8: 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 towards the bottom
of the casing (6 o’clock position).
HXL10: Using a hoist, place the disc (71) on the head
with the counterbored screw holes facing out. The word
“INTAKE” on the disc should be positioned so that it
faces the intake side of the pump when the head is
attached to the casing with the head drain hole towards
the bottom of the pump. Install the six (6) disc retaining
screws (71A) and lockwashers (71B).
7. Install a new head O-ring (72).
8. 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).
9. The mechanical seal components and the bearing must
be installed before attaching hub to head.
a. Apply a small amount of motor oil on the shaft
between the shaft threads and the rotor. Wrap tape
over the shaft threads to prevent damage to
mechanical seal O-rings.
b. Slide the seal jacket assembly over the shaft and
into the seal cavity with the drive tangs of the jacket
towards the rotor. Rotate the jacket assembly to
engage the drive tangs in the rotor slots.
c. Install a new rotating O-ring (153L) in the rotating
seal face (153F). Align and insert the rotating
assembly into the the seal jacket with the polished
face outward. Clean the polished face with a clean
tissue and alcohol. Bronze seal faces should be
oiled during installation, but other seal faces must be
kept clean and dry. Note: Carbon/PTFE rotating
seal face (153M) is installed as a one-piece
assembly.
d. Apply a small amount of motor oil in the hub seal
recess.
e. 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.
f. Install seal retaining screws and washers (153Q,
153R, 153S).
g. Hand pack the ball bearing (24) with grease. Refer
to the "Lubrication" section for the recommended
grease.
h. Install the bearing into the recess of the hub (20C).
i. Temporarily attach the bearing cover (27) and
gasket (26) to hub and hand tighten capscrews (28).
j. 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” on
10. 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.
11. Set the pump upright.
12. Remove the outboard head and disc temporarily
attached earlier.
13. Complete assembly on the OUTBOARD side of the
pump as instructed for the inboard side in steps 6 -10,
leaving the head capscrews loosely tightened.
14. 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: HXL8 and HXL10 MODELS
15. 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
6.
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 6 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.
16. 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.
17. 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.
18. 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"
19. Reinstall coupling, shaft key, and coupling guards.
20. Refer to “Pre-Start Up Check List” and “Start Up
Procedures” sections of this manual prior to pump
operation.

102-A00 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. Air leaks in the suction line.
6. Strainer clogged.
7. Suction line or valves clogged or too restrictive.
8. Broken drive train.
9. Pump vapor-locked.
10. Pump speed too low for priming.
11. Relief valve partially open, worn or not seating properly.
12. Vanes installed incorrectly (see "Vane Replacement").
13. Incorrect Rotation
Reduced Capacity
1. Pump speed too low.
2. Suction valves not fully open.
3. Air leaks in the suction line.
4. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows &
fittings, clogged strainer, etc.).
5. Damaged or worn parts (vanes, discs, liner or rotor).
6. Excessive restriction in discharge line causing partial flow through the relief valve.
7. Relief Valve worn, set too low, or not seating properly.
8. Vanes installed incorrectly (see "Vane Replacement").
9. Liner installed backwards.
Noise
1. Excessive vacuum on the pump due to: (or: Excessive pressure drop in suction
line due to:)
a. Undersized or restricted fittings in the suction line.
b. Pump speed too fast for the viscosity or volatility of the liquid.
c. Pump too far from fluid source.
d. Suction Lift too great.
2. Entrained Air or Vapor in the pumpage.
3. Running the pump for extended periods with a closed discharge line.
4. Pump not securely mounted.
5. Misalignment of pump, reducer or motor.
6. Improper drive line (see "Pump Drive").
7. Bearings worn or damaged.
8. Vibration from improperly anchored piping.
9. Bent shaft, or drive coupling misaligned.
10. Insufficient oil in the gear reducer.
11. Excessively worn rotor.
12. Malfunctioning valve in the system.
13. Relief valve setting too low.
14. Liner installed backwards.
15. Damaged vanes (see following category).

102-A00 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. Viscosity too high for the vanes and /or the pump speed.
5. Incompatibility with the liquids pumped.
6. Excessive heat.
7. Worn or bent push rods, or worn push rod holes.
8. Settled or solidified material in the pump at start-up.
9. Hydraulic hammer - pressure spikes.
10. Vanes installed incorrectly (see"Vane Replacement").
Broken Shaft
1. Foreign objects entering the pump.
2. Viscosity too high for the pump speed.
3. Relief valve not opening.
4. Hydraulic hammer - pressure spikes.
5. Pump/driver, driveline/drive shaft misalignment.
6. Excessively worn vanes or vane slots.
7. Settled or solidified material in the pump at start-up.
8. Overtightened V-belts, if used.
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. Pump sleeve bearings worn excessively.
6. Excessive cavitation.
9.
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.

102-A00 page 16/16
1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A.
Telephone: [phone] • Fax: [phone]
E-mail: blackmer @blackmer.com • Internet Address: www .blackmer.com