BLACKMER XLW2F Manual

BLACKMER POWER PUMPS 963907
INSTRUCTIONS NO. 105-B00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS
MODELS: XLW2F, XLW3F, XLW4A
DISCONTINUED MODELS: XLW2E-N, XLW3E-N
Section
Effective
Replaces
105
Jul 2018
Jul 2015
TABLE OF CONTENTS Page
PUMP DAT
A
Technical Data 2
Initial Pump Start Up Information 2
INSTALLATION
Pre-Installation Cleaning 3
Location and Piping 3
Mounting - Stationary 3
Mounting - Truck 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 6
Running the Pump in Reverse Rotation 6
Flushing the Pump 6
Pump Relief Valve 6
Relief Valve Setting and Adjustment 7
MAINTENANCE
Lubrication 7
Strainers 8
Vane Replacement 8
Pump Disassembly 8
Parts Replacement 8
Pump Assembly 9
FLANGE MOUNTED GEAR REDUCER MAIN. 12
TROUBLE SHOOTING 14
NOTE:
Numbers in parentheses following individual parts indicate
reference numbers on Blackmer Parts List No. 105-B01,
105-B02 and 105-B04.
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 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 the Blackmer XLW Series 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.

105-B00 page 2/16
SAFETY DATA
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Hazardous
machinery can
cause serious
personal injury. Hazardous voltage.
Can shock, burn or
cause death.
If pumping hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
performing service or maintenance
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property damage
Hazardous or toxic
fluids can cause
serious injury. Hazardous pressure
can cause personal
injury or property
damage
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
Do not operate
without guard
in place Hazardous pressure
can cause personal
injury or property
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
XLW2
XLW3 XLW4
Maximum Pump Speed 350 RPM 350 RPM
Maximum Operating
Temperature 300°F
(149°C) 300°F (149°C)
Maximum Viscosity 75,000 SSU
(15,750 cP) 20,000 SSU (4,250 cP)
Maximum Differential
Pressure 150 psi
(10.3 Bar) 150 psi (10.3 Bar)
Maximum Working
Pressure 350 psi
(24.1 Bar) 350 psi (24.1 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: ____________________________________

105-B00 page 3/16
INSTALLATION
NOTICE:
Blackmer 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
Pump life and performance can be significantly reduced
when installed in an improperly designed system. Before
starting the layout and installation of the piping system,
review the following:
1. Locate the pump as near as possible to the source of
supply to avoid excessive inlet pipe friction.
2. The inlet line MUST be at least as large as the intake
port on the pump. It should slope downward to the
pump, and should not contain any upward loops.
Eliminate restrictions such as sharp bends; globe
valves, unnecessary elbows, and undersized strainers.
3. It is recommended a strainer be installed in the inlet line
to protect the pump from foreign matter. The strainer
should be located at least 24" (0.6m) from the pump,
and have a net open area of at least four times the area
of the intake piping. Strainers must be cleaned regularly
to avoid pump starvation.
4. The intake system must be free of air leaks.
5. 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.
6. Install pressure gauges in the NPT ports provided in the
pump casing to check pump at start up.
7. ALL piping and fittings MUST be properly supported to
prevent any piping loads from being placed on the
pump.
8. 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
9. 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 - STATIONARY
A solid foundation reduces noise and vibration, and will
improve pump performance. On permanent installations it is
recommended the pumping unit be secured by anchor bolts
as shown in Figure 2. This arrangement allows for slight
shifting of position to accommodate alignment with the
mounting holes in the base plate.
Figure 2 - Pipe Type Anchor Bolt Box
For new foundations, it is suggested that the anchor bolts be
set in concrete. When pumps are to be located on existing
concrete floors, holes should be drilled into the concrete to
hold the anchor bolts.
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.
PUMP MOUNTING - TRUCK
If the pump is to be mounted on a truck and driven via a PTO
shaft or hydraulic motor, please refer to Blackmer Form 578..

105-B00 Page 4/16
COUPLING ALIGNMENT – LONG
COUPLED
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.
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" (.127 mm).
2. Angular alignment: Insert a feeler gauge between the
coupling halves. Check the spacing at 90° increments
around the coupling (four checkpoints). Maximum
variation should not exceed .005" (.127 mm). Some
laser alignment tools will check angular alignment as
well.
3. Replace the coupling guards after setting alignment.
Figure 3 – Alignment Check
ALIGNMENT – FLANGE MOUNTED GEAR
REDUCER
If the unit is assembled with a Blackmer Flange Mounted Gear
Reducer, no coupling alignment is required. The motor,
gearbox, and pump are rigidly connected with bolted, flange
connections. These flanges ensure the motor shaft, gearbox
shafts, and pump shaft are aligned correctly, without the need
for manual alignment. However, due to variations in base and
foundation geometry the unit will require shimming to reduce
stress on the gearbox and pump adapter. See PRESTART
CHECKLIST section for details.
PUMP ROTATION
A right-hand pump rotates clockwise with the intake on the
right side, when viewed from the driven end.
A left-hand pump rotates counterclockwise with the intake on
the left side, when viewed from the driven end.
TO REVERSE PUMP ROTATION
To reverse rotation, the pump must be disassembled then
reassembled with the shaft on the opposite side of the pump.
See the ‘Maintenance’ section for instructions.
CHECK VALVES
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.

105-B00 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 personal
injury or property
damage
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
Hazardous pressure
can cause 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 on long coupled units.
3. For units assembled with a Blackmer Flange Mounted
Gearbox:
3a. Bolt down the pump foot, while supporting the motor
with an appropriate lifting device (e.g. crane)
3b. Place a .125” thick shim under each of the motor
mounting holes
3c. Slowly lower the motor until it is unsupported
3d. Try pulling out each of the shims, while noticing the
the pull tension
3e. If the shims closest to the motor shaft easily pull out,
increase the shim thickness the same at all
locations and recheck
3f. If the shims furthest from the motor shaft easily pull
out, decrease the shim thickness the same at all
locations and recheck
3g. The unit is properly shimmed when all 4 motor
shims have the same amount of tension when
pulled
3h. Bolt down the motor with the appropriate fastener.
4. Blackmer Flange Mounted Gearboxes will be shipped
with Mobil SHC630 synthetic oil. If replacing the oil,
refer to the FLANGE MOUNTED GEAR REDUCER
MAINTENANCE section.
5. Blackmer helical gear reducers (if supplied) are shipped
from the factory without oil in the gearcase. Fill with the
grade of oil indicated on the reducer tag. For more
specific instructions on Blackmer gear reducers, refer to
the appropriate Gear reducer Installation, Operation
and Instruction Manual.
6. Check the entire pumping system to verify that the
proper inlet and discharge valves are fully open, and
that the drain valves and other auxiliary valves are
closed.
7. Install vacuum and pressure gauges on the pump in the
1/4” NPT connections provided to check suction and
discharge conditions after pump start-up.
8. Check the wiring of the motor, and briefly turn on the
power to make sure that the pump rotates in the
direction of the rotation arrow.

105-B00 Page 6/16
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 suction and discharge pressure to see if the
pump is operating within the expected conditions.
Record pressures in the ‘Initial Start Up Information’
section.
3. Check for leakage from the piping and equipment.
4. Check for overheating, excessive noise or vibration of the
pump, reducer, and motor.
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 briefly
closing a valve in the discharge line and reading the
pressure gauge. This pressure should be 20 psi (1.4 bar)
higher than the maximum operating pressure.
Do not run the pump for more than 10-15 seconds
with the discharge valve completely closed.
If adjustments need to be made, refer to "Relief Valve
Setting & 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
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.
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. The valve in the discharge line
should be restricted to build up 10 psi (0.7 bar) to force
flushing liquid through the bearing seal chamber.
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.
XLW series pumps are fitted with an internal pressure relief
valve that bypasses back to the suction side of the pump.
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.

105-B00 Page 7/16
RELIEF VALVE SETTING AND ADJUSTMENT
The relief valve pressure setting is marked on a metal tag
attached to the valve cover. Generally, the relief valve should
be set at least 15 - 20 psi (1.0 - 1.4 Bar) higher than the
operating pressure, or the external bypass valve setting (if
equipped).
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.
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.
MAINTENANCE:
NOTICE:
Maintenance shall be performed by qualified technicians
only, following the appropriate procedures and warnings
as presented in this manual.
SCHEDULED MAINTENANCE
Failure to disconnect and lockout
electrical power or engine drive
before attempting maintenance can
cause severe personal injury or death
Hazardous
machinery can
cause serious
personal injury.
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
or death
Hazardous voltage.
Can shock, burn or
cause death.
Failure to relieve system pressure
prior to performing pump service or
maintenance can cause personal
injury or property damage.
Hazardous pressure
can cause 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.
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.
Pump bearings should be lubricated every one to twelve
weeks (AT MINIMUM), depending on the application, and
operating conditions.
Recommended Grease:
Mobil® - Mobilgrease XHP222,
or equivalent.
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
covers (27A).
2. SLOWLY apply grease with a hand gun until grease
begins to escape from the grease relief fitting port.
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 on pumps equipped with
mechanical seals can cause seal failure.
If equipped: Blackmer gear reducers are shipped from the
factory without oil in the gearcase. Fill with the grade of oil
indicated on the reducer tag. The oil should be changed after
the first 48 hours of use and approximately every 500 hours
of use thereafter.

107-B00 Page 8/16
STRAINERS
Strainers must be cleaned regularly to avoid pump starvation.
Schedule will depend upon the application and conditions.
VANE REPLACEMENT
NOTICE:
Maintenance shall be performed by qualified technicians
only, following the appropriate procedures and warnings
as presented in manual.
1. Flush the pump per instructions in this manual. Drain and
relieve pressure from the pump and system as required.
2. 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.
3. Turn the shaft by hand until a vane comes to the top (12
o'clock) position of the rotor. Remove the vane.
4. Install a new vane, ensuring that the rounded edge is UP,
and the relief grooves are facing towards the direction of
rotation. See Figure 4.
5. 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.
6. Reassemble the pump according to the "Pump
Assembly." section of this manual.
Figure 4 – Vane Replacement
PUMP DISASSEMBLY
NOTICE:
Follow all hazard warnings and instructions provided in
the “maintenance” section of this manual.
NOTE: The numbers in parentheses following individual
parts indicate reference numbers on the Pump Parts List.
1. Flush the pump per instructions in this manual. Drain and
relieve pressure from the pump and system as required.
2. Starting on the inboard (driven) end of the pump, 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. 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. On 2-inch
pump models, the dirt shield will slide off with the bearing
cover.
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. To remove 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 head capscrews (21). Gently pry the head
away from the casing using two large screwdrivers. The
head O-ring should come off with the head assembly.
7. Slide the head and O-ring off the shaft. The bearing (24),
mechanical seal stationary seat and stationary O-ring
(153A & 153D) will come off with the head assembly.
a. On 4-inch models, remove the disc from the head by
removing the disc machine screws (71A) and
lockwashers (71B). The mechanical seal rotating
assembly (153B, 153C, 153E) will be released when
the disc is removed.
b. Pull the bearing (24) from the housing in the head.
c. To remove the mechanical seal stationary seat
(153A), use the blunt end of a screw driver to gently
push the backside of the stationary seat from the
head. 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.
8. On 2 and 3-inch models, carefully pull the rotating seal
assembly, including seal jacket (153C), rotating seal face
and rotating O-ring (153B & 153E) from the shaft.
Remove and discard the rotating O-ring. Remove the disc
(71).
9. Pull the rotor and shaft (13) from the casing. While one
hand is pulling the shaft, the other hand should be
cupped underneath the rotor to prevent the vanes (14)
and pushrods (77) from falling out. Carefully set the rotor
and shaft aside for future vane replacement and
reassembly.
10. Lay the pump flat with the remaining head facing upward
to remove the outboard head assembly, mechanical seal
and disc from the outboard side of the pump, as
instructed in steps 6 - 8.
11. If necessary, remove the liner (41) by tapping around the
outside diameter of the liner with a hard wood drift and a
hammer until it is driven from the casing.
PARTS REPLACEMENT
1. If any of the O-rings have been removed or disturbed
during disassembly, they be replaced with new O-rings.
NOTE: PTFE O-rings should be heated in hot water to
aid installation.
2. Excessive or continuous leakage from the tell-tale hole in
the bearing cover may be an indication of a damaged
mechanical seal. If a mechanical seal has been leaking, it
is recommended the entire seal be replaced. Refer to
"General Pump Troubleshooting" for possible causes of
seal leakage.

107-B00 Page 9/16
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.
Reassemble the OUTBOARD side of the pump first:
For a CLOCKWISE rotation pump, position the pump
cylinder with the INTAKE port to the left.
For a COUNTERCLOCKWISE rotation pump, position
the pump cylinder with the INTAKE port to the right.
1. Install the liner key (74) in the slot located in the top of the
liner. Align the key with the notch in the top of the pump
casing and start the liner into the casing.
The word “INTAKE” cast on the liner must face the intake
port of the pump casing. Uniformly tap the outer edge of
the liner with a rubber mallet to fully insert into the casing.
2. On 2 and 3-inch models, place the disc (71) against the
liner with the seal cavity outward.
3. On 4-inch models, attach the disc to the outboard head
without the mechanical seal components. Install disc
machine screws (71A) and lockwashers (71B)
4. Without installing the head O-ring or mechanical seal
components, temporarily attach the outboard head and
bearing to the casing. Install and hand-tighten two head
capscrews, 180 degrees apart. This head will be used to
hold and align the rotor and shaft while the inboard side
of the pump is assembled.
5. Turn the pump around to begin assembly on the inboard
side. Before installing the rotor & shaft assembly, the
direction of pump rotation must be determined as
indicated under the “Pump Rotation” section of this
manual.
Figure 5 – Pushrod Installation
6. 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 vanes into the bottom three rotor slots with
the relief grooves facing in the direction of pump
rotation, and with the rounded edges outward. See
Figure 4.
b. Hold the three bottom vanes in place while inserting
the three push rods (77). See Figure 5.
c. After the bottom vanes and push rods are installed,
carefully insert the non-driven end of rotor and shaft
into the casing.
d. Install the remaining vanes into the top positions of
the rotor.
7. DISC – 2 and 3-inch Models
Install the disc (71) on the inboard side of the pump with
the seal cavity facing outward and the disc relief hole
located as shown in Figure 6.
Figure 6 – Disc Relief Hole Location
2 and 3-inch Models
8. MECHANICAL SEAL – 2 and 3-inch Models
Rotating Assembly
a. Apply a small amount of motor oil on the shaft
between the shaft threads and the rotor.
b. Slide the seal jacket assembly (153C) over the shaft
and into the disc 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 (153E) in the rotating seal
face (153B). 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.
Stationary Seat
a. Apply a small amount of motor oil in the seal access
of the head.
b. Install a new stationary O-ring (153D) in the stationary
seat (153A). Clean the polished face with a clean
tissue and alcohol. Align the pin in the stationary seat
with the slot in the head recess and push the seat
fully into the seal recess with the polished face
outward.
9. DISC and MECHANICAL SEAL – 4-inch Models
a. Before attaching the disc, apply a small amount of
motor oil in the recess of the head.
b. Install a new stationary O-ring (153D) in the
stationary seat (153A). Align the pin in the stationary
seat with the slot in the head recess and push the
seat fully into the seal recess with the polished face
outward. Clean the polished face with a clean tissue
and alcohol.
c. Install a new rotating O-ring (153E) in the rotating
seal face (153B). Clean the polished face with a
clean tissue and alcohol. Place the polished face of
the rotating seal against the face of the stationary
seat in the head.
d. Align and install the seal jacket assembly (153C)
over the rotating face with the drive tangs outward.
e. Carefully place the disc on the head with the seal
cavity inward. The drive tangs of the seal jacket
should protrude through the center hole of the disc.

107-B00 Page 10/16
f. Position the disc relief hole so that when the head is
mounted on the pump with the “Blackmer” name in
an upright position, the disc hole will be towards the
INTAKE side of the pump. See Figure 7.
g. Install the disc machine screws (71A) and
lockwashers (71B).
Figure 7 – Disc Relief Hole Location (4-inch Models)
10. Install a new head O-ring (72) in the groove on the inside
face of the head. Lay the O-ring flat and start in on one
side of the groove, stretching ahead with the fingers, as
shown in Figure 7.
Figure 7 – Head O-Ring Installation
11. Carefully install the head assembly (20) over the shaft.
Do not contact the end of the shaft with the mechanical
seal. Position the head with the small weep hole towards
the bottom of the pump. Install and partially tighten four
head capscrews (21) 90° apart. The remaining capscrews
will be installed in step 18.
On 4-inch models, make sure the head is mounted with
the “Blackmer” name upright and the disc relief hole
towards the intake side of the pump. The seal jacket drive
tangs must be engaged in the rotor slots.
12. Hand pack the ball bearing (24) with grease. Refer to the
"Lubrication" section for the recommended grease.
13. Install the bearing into the head recess. The bearing balls
should face outward, with the grease shield (ref. 123, 2”
models only) inward. The bearing must be fully and
squarely seated in the head.
14. Turn the pump casing around and remove the outboard
head and disc previously installed.
15. Install the mechanical seal and disc in the outboard head
as instructed in steps 7 through 8 for the 2 and 3-inch
models or step 9 for the 4-inch models.
16. Finish assembling the outboard side of the pump as
instructed in steps 10 through 13.
17. Rotate the shaft by hand to engage the mechanical seal
drive tangs, and 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.
18. Install and partially tighten the remaining head capscrews
19. Uniformly torque the head capscrews to 30 lbs ft (40.7
Nm), alternating between one side of the head and the
other. Frequently check that the shaft still turns freely. If
tight, loosen the capscrews and repeat the procedure. If
the shaft continues to bind, check for grease or dirt on the
mechanical seal faces.
Figure 8 – Locknut Assembly
20. LOCKNUT ADJUSTMENT
It is important that the bearing locknuts (24A) and
lockwashers (24B) be installed and adjusted properly.
Overtightening locknuts can cause bearing failure or a
broken lockwasher tang. Loose locknuts will allow the
rotor to shift against the discs, causing wear. See Fig. 8.
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.
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 “B”.
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.
g. To check adjustment, grasp the nut and washer with
fingers and rotate back and forth. If this cannot be
done, one or both locknuts are too tight and should be
alternately loosened one stop at a time 0.001"
(0.025mm). Begin by loosening the locknut adjusted
last.
21. 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 inward (towards the pump).
22. Attach a new bearing cover gasket (26) and the inboard
bearing cover (27A) to the inboard head. Install the
outboard bearing cover (27) and a new gasket to the
outboard head. Make sure the grease fittings (76) on the
bearing covers are accessible. Install and torque the
bearing cover capscrews (28) to 30 lbs ft (40.7 Nm).

107-B00 Page 11/16
23. RELIEF VALVE ASSEMBLY
a. Insert the valve (9) into the relief valve bore of the
casing with the fluted end inward.
b. Install the relief valve spring (8) and spring guide (7)
against the valve.
c. Attach a new relief valve O-ring (10) and the valve
cover (4) on the cylinder.
d. Screw the relief valve adjusting screw (2) with locknut
(3) into the valve cover (4) until it makes contact with
the spring guide (7).
e. After the relief valve has been adjusted, tighten the
Locknut (3) and install the relief valve cap (1) and O-
ring (88) 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"
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard in
place.
24. Reinstall coupling, shaft key, and coupling guards.
25. Refer to “Pre-Start Up Check List” and “Start Up
Procedures” sections of this manual prior to restarting
pump operation.

101-C00 Page 12/16
FLANGE MOUNTED GEAR REDUCER MAINTENANCE
NOTICE:
Detailed maintenance instructions for the gearbox
can be found at www.nord.com/docs. The
following are excerpts from those documents and
should be treated as reference only.
STORAGE NOTICE:
For storage periods longer than 9 months, or for
storage in less than desirable conditions, please
consult NORD for recommendations.
Storage for up to 9 months is possible, so long as the
following conditions are observed:
Store the gear unit in its actual mounting position in
accordance with the specified oil fill-level, in a clean and
dry temperature controlled area. Avoid temperature
fluctuations within the range of 0°C and 40°C (32°F to
104°F) and avoid relative humidity conditions in excess
of 60%.
Protect all exposed or unpainted shaft and flange
surfaces with an anti-corrosion agent or grease.
Store in a location free from shock and vibration, to
avoid false brinelling of bearing elements and
raceways.
Whenever possible, rotate the shafts periodically, by
hand if necessary, to help prevent brinelling (bearing
damage) and to help keep the shaft seals pliable.
Avoid direct exposure to the sun or UV light and
aggressive or corrosive materials in the environment
(ozone, gases, solvents, acids, caustic solutions, salts,
radioactivity, etc.
Commissioning
Prior to gear unit start-up, complete the following:
Please check your gear unit for a vent and if applicable
to your product, remove the sealing plug to activate
NOTICE:
To prevent build-up of excessive pressure, sealed
vents must be activated as shown prior to gear
unit start up. Excessive pressure may cause
damage to internal gearbox components and
leakage.
Check the lubricant and be sure the gear unit is filled
with the proper oil type, to the proper level, as
determined by the mounting position.
Check the condition of all shaft seals and all assembled
flange gasket areas. If any change is detected in the
shape, color, hardness or permeability, or if any leaks
are detected, the corresponding shaft seals and/or
gaskets must be replaced.
Remove all anti-corrosive metal protectant from
otherwise bare metal surfaces. Follow product
manufacturer’s directions and warnings during surface
protection removal.
Check the resistance of all motor and brake windings to
verify the integrity of the winding insulation and inspect
all terminal box openings and wire connection areas to
verify that all components are dry and free of corrosion.
Long Term Storage
By taking special precautions, problems such as seal
leakage and reducer failure due to the lack of lubrication,
improper lubrication quantity, or contamination can be
avoided. The following precautions will protect gear
reducers during periods of extended storage:
Store the gear unit in its actual mounting position in
accordance with the specified oil fill-level, in a clean and
dry temperature controlled area. Avoid temperature
fluctuations within the range of 0°C and 40°C (32°F to
104°F) and avoid relative humidity conditions in excess
of 60%.
Fill the reducer full with oil that is compatible with the
product normally used or recommended during service.
Apply grease to all unpainted or unprotected shafts,
bores, keyways, flange surfaces, tapped holes, and to
the exterior of all oil seals.
Store in a location free from shock and vibration, to
avoid false brinelling of bearing elements and
raceways.
Once every few months rotate the input shaft
approximately 10-20 revolutions to redistribute the
weight of gears and shafts and to prevent brinnelling of
the bearings and drying of the seal track.
Avoid direct exposure to the sun or UV light and
aggressive or corrosive materials in the environment
(ozone, gases, solvents, acids, caustic solutions, salts,
radioactivity, etc.)
Commissioning After Long-Term Storage
Please check your gear unit for a vent and if applicable
to your product, remove the sealing plug to activate.
NOTICE:
To prevent build-up of excessive pressure, sealed vents
must be activated as shown prior to gear unit start
up.Excessive pressure may cause damage to internal
gearbox components and leakage.
Remove all anti-corrosive metal protectant from
otherwise bare metal surfaces. Follow product
manufacturer’s directions and warnings during surface
protection removal.
Drain the reducer and refill it with the proper type and
amount of lubricant.
Observe start-up and initial operation to make sure
there are no seal or gasket leaks, or unusual sounds,
vibration or heat rise during operation.
Check the resistance of all motor and brake windings to
verify the integrity of the winding insulation and inspect
all terminal box openings and wire connection areas to
verify that all components are dry and free of corrosion.

105-B00 Page 13/16
UP
Lubrication
Proper gearbox lubrication is essential in order to reduce
friction, heat, and component wear. Lubricants reduce heat
and wear by inserting a protective “fluid boundary” between
mating parts and preventing direct metal to metal contact.
Lubricants also help prevent corrosion and oxidation,
minimize foam, improve heat transfer, optimize reducer
efficiency, absorb shock loads and reduce noise. Most
NORD reducers are shipped from the factory with a pre-
determined oil fiIl level in accordance to the specified
reducer size and mounting position.
The standard orientation for the gearbox is shown in Figure
9. The gearbox is filled with the correct amount of oil and is
the correct configuration for this orientation. For any other
orientation, please consult the factory.
Lubrication Table
ISO
Viscosity Oil Type Ambient Temp Range (°F) Brand
V
G220 PAO -31 to 140 Mobil SHC630*
VG220 MIN-EP 32 to 104 Mobilgear
600XP220
VG220 FG 23 to 104 Fuchs FM220
VG460 PAO -31 to 176 Mobil SHC 634
*Standard Oil Shipped with Gearbox
Oil Formulation Codes:
MIN-EP - Mineral Oil with EP Additive
PAO - Synthetic Polyalphaolefin Oil
FG - Food-Grade Oil
NOTICE:
The “Ambient Temperature” is intended to be an
operation guideline based upon the typical properties of
all the lubricant. The viscosity and other properties of
the lubricant change based upon load, speed, ambient
conditions, and reducer operating temperatures. The
user should consult with their lubrication supplier &
NORD gear before considering changes in oil type or
viscosity.
To prevent reducer overheating, observe the
maximum operating oil temperature limits:
Mineral Oil: 176 – 180 °F
Synthetic Oil: 225 °F
In the following instances, please consult NORD for
specific recommendations:
oGear units will operate in high ambient
temperature conditions exceeding 40 oC
(104 oF).
oGear units will operate in cold ambient
temperature conditions approaching 0 oC
(32 oF) or lower.
oLower than an ISO VG100 viscosity oil is
being considered for a cold-temperature
service.
oFluid grease is required for lubricating the
gear unit.
Observe the general lubrication guidelines outlined
in user manual U10750.
NOTICE:
Do not to mix different oils with different additive
packages or different base oil formulation types.
Polyglycol (PG) oils are not miscible with other oil types
and should never be mixed with mineral oil or
polyalphaolefin (PAO) synthetic oil.
Figure 9 – Standard Gear Reducer Orientation

105-B00 Page 14/16
PUMP TROUBLESHOOTING
NOTICE:
Maintenance shall be performed by qualified technicians only,
following the appropriate procedures and warnings as presented in this manual.
LEAKAGE
Location Probable Cause/Corrective Action
Between the head & casing Damaged head O-ring: Inspect and replace if necessary.
Burrs/dirt in head O-ring groove or cylinder: File and clean as necessary.
Around the shaft New Mechanical Seals: New seals may leak slightly at start up, but
should seal up shortly thereafter.
Damaged mechanical seals: Check for damaged O-rings or cracked,
scratched or worn seal faces
SHAFT BINDING
Probable Cause Corrective Action
Burrs, dirt or foreign particles on the heads or discs. During assembly, both heads and discs must be clean and smooth. File
any burrs or rough spots, and wipe the discs with a clean cloth and
alcohol to remove any dirt or foreign particles.
Improper locknut adjustment. Locknuts must be adjusted properly to center the rotor and shaft between
the heads. Refer to "Locknut Installation" on Page 10.
Contaminated mechanical seal faces. Any trace of grease or dirt on the seal faces will prevent the faces from
mating properly, causing the rotor and shaft to bind or turn hard. Use a
tissue paper & alcohol to clean the seal faces. NOTE: Apply a light oil or
suitable lubricant to bronze seal faces only.
OTHER POSSIBLE CAUSES OF SHAFT BINDING:
• Foreign particles on rotor, liner or vanes.
• Damaged vanes or rotor. • Bent push rods. • Liquids that "set up" when inactive.
OVERHEATING
Probable Cause Corrective Action
Continual, full bypassing of the liquid. The relief valve should be adjusted such that the pump will not bypass
during normal operation. WARNING: Internal bypassing of liquid
elevates the liquid temperature. The internal bypass valve should
only be used for brief periods and at differential pressures below
125 psi.
For extended periods of higher pressures, the internal bypass port
must be plugged and the liquid returned back to the source.
OTHER POSSIBLE CAUSES OF OVERHEATING:
• Improper relief valve adjustment
(See "Relief Valve" on Page 3). • Plugged discharge line.
• Closed valve.

105-B00 Page 15/16
PUMP TROUBLESHOOTING
LOW DELIVERY RATE
Probable Cause Corrective Action
Relief valve setting too low, causing the liquid to
bypass. The relief valve setting should be 20 psi (1.4 bar) higher than the
differential pressure.
OTHER POSSIBLE CAUSES OF A LOW DELIVERY
RATE:
Check pipe joints for leakage of air. Sometimes when recirculating liquid
in a tank, the returning liquid falling through the air carries air down
into the tank, which eventually gets back into the pump.
Restriction in the suction line.
Suction valve not fully open.
Resistance in the discharge line.
Air leaks in the suction line.
Damaged or worn pump parts.
Pump speed too low or too high.
Relief valve leaking.
Relief valve sticking open, or not properly seating.
Dirty strainer.
Liner installed backwards
Vanes install incorrectly
Excessive restriction in discharge line causing RV to open.
EXCESSIVE NOISE AND VIBRATION
Probable Cause Corrective Action
Cavitation or vaporization of the liquid resulting from
excessive vacuum on the pump due to starved
suction.
Check for:
Inlet piping too long or too small in diameter.
Strainer plugged or dirty.
Undersized or restrictive fittings, such as globe valves or partially
closed valves.
Excessive amount of elbows.
Suction lift too great.
Pump speed too high for the viscosity of the liquid being pumped.
Entrained air or vapors in the pump. Check pipe joints for leakage of air. Sometimes when recirculating liquid
in a tank, the returning liquid falling through the air carries air down
into the tank, which eventually gets back into the pump.
Pump speeds exceed the recommended maximum. Check the recommended RPM for your specific application.
Liner Installed Backwards The word “INTAKE”, which is cast on the liner MUST be towards the
intake side of the pump
Continual or long term bypassing of liquid through
relief valve. Check for restriction in the discharge line, or an improper relief valve adjustment (See "Relief Valve" on Page 6).
OTHER POSSIBLE CAUSES OF NOISE AND VIBRATION:
Excessively worn vanes, discs or rotor.
Bearing Worn or Damaged.
Loose or improperly installed piping.
Misalignment of pump and driver or bent shaft.
Pump base not properly mounted.
Insufficient Oil in the Gear Reducer
POOR OR NO PRIMING
Probable Cause
Air leaks in the suction line.
Valve partially closed or other restriction in the
suction line.
Damaged or worn pump parts.
Too much lift for the vapor pressure of the fluid.
A dirty or clogged strainer.
Worn vanes.
Suction Valve Closed.
Incorrect pump rotation
Relief Valve partially open, valve not seating properly.
Pump speed too low for priming

105-B00 Page 16/16
PUMP TROUBLESHOOTING
DAMAGED VANES
Probable Cause
Foreign objects entering the pump.
Running the pump dry for extended periods of
time.
Cavitation.
Viscosity too high for the vanes and /or the pump
speed.
Incompatibility with the liquids pumped.
Excessive heat.
Worn or bent push rods, or worn push rod holes.
Settled or solidified material in the pump at start-up.
Hydraulic hammer - pressure spikes.
Vanes installed incorrectly (see"Vane Replacement").
BROKEN SHAFT
Probable Cause
Foreign objects entering the pump.
Viscosity too high for the pump speed.
Relief valve not opening.
Hydraulic hammer - pressure spikes.
Pump/driver, driveline/drive shaft misalignment.
Excessively worn vanes or vane slots.
Settled or solidified material in the pump at start-up.
Overtightened V-belts, if used.
SEAL LEAKAGE
Probable Cause
O-rings not compatible with the liquids pumped.
O-rings nicked, cut or twisted.
Shaft at seal area damaged, worn or dirty.
Excessive cavitation.
Mechanical seal faces cracked, scratched, pitted or dirty.
Ball bearings overgreased.
MOTOR OVERLOAD
Probable Cause
Horsepower of motor not sufficient for application
Improper wire size / wiring and/or voltage to motor.
Misalignment in pump drive system.
Bearing locknuts adjusted improperly.
Excessive viscosity, pressure or speed.
Faulty or worn bearings.
Rotor rubbing against head or liner.
Dirty mechanical seal faces.
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