BLACKMER XRLW1.25A Manual

BLACKMER POWER PUMPS 962304
INSTRUCTIONS NO. 105-A00_apr05
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS Section
Effective
Replaces
105
April 2005
June 2003
DISCONTINUED MODELS: XRLW1.25A, XLW1.25A, XLW1.5A
XRLW1¼, XLW1¼, XLW1½
TABLE OF CONTENTS Page
PUMP DATA
Technical Data .................................................... 2
Initial Pump Start Up Information.........................2
INSTALLATION
Pre-Installation Cleaning ..................................... 3
Location and Piping.............................................3
Check Valves ......................................................3
Mounting .............................................................3
Coupling Alignment.............................................4
Pump Rotation.....................................................4
To Change Pump Rotation.................................. 4
OPERATION
Pre-Start Up Check List.......................................4
Start Up Procedures............................................5
Flushing the Pump ..............................................5
Pump Relief Valve...............................................5
Relief Valve Setting and Adjustment................... 5
MAINTENANCE
Strainers................................................................. 6
Lubrication..............................................................6
Vane Replacement................................................. 7
Pump Disassembly ................................................7
Parts Replacement................................................. 7
Pump Assembly.....................................................8
TROUBLE SHOOTING ............................................... 10
NOTE: Numbers in parentheses following individual parts
indicate reference numbers on Blackmer Parts List No.
105-A01.
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 the Blackmer power pumps, and
MUST be kept with the pump.
Blackmer power 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 Blackmer power pumps.
Maintain ALL system and Blackmer power pump
operation and hazard warning decals.
Aug 2007: Discontinued models, parts availability may be limited.

105-A00 page 2/12
SAFETY DATA
Hazardous
machinery can
cause serious
personal injury.
FAILURE TO DISCONNNECT AND
LOCKOUT ELECTRICAL POWER OR
ENGINE DRIVE BEFORE ATTEMPTING
MAINTENANCE CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH Hazardous voltage.
Can shock, burn or
cause death.
FAILURE TO DISCONNECT AND
LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING MAINTENANCE
CAN CAUSE SHOCK, BURNS OR
DEATH
Hazardous or toxic
fluids can cause
serious injury.
IF PUMPING HAZARDOUS OR TOXIC
FLUIDS, SYSTEM MUST BE FLUSHED
AND DECONTAMINATED, INSIDE AND
OUT, PRIOR TO PERFORMING SERVICE
OR MAINTENANCE 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.
Do not operate
without guard
in place
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
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.
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
Maximum Pump Speed 870 RPM
Maximum Operating Temperature 240°F (115°C)
Maximum Differential Pressure 150 psi (10.3 Bar)
Maximum Working Pressure 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-A00 page 3/12
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.
Hazardous voltage.
Can shock, burn or
cause death.
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.
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 will be significantly reduced when
installed in an improperly designed system. Before starting the
layout and installation of the piping system, review the
following suggestions:
1. Locate the pump as near as possible to the source of
supply to avoid excessive inlet pipe friction.
2. The inlet line should 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. A strainer must 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 and discharge piping system must be free of all
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 performance at startup.
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 2. 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 2
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.
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.
PUMP MOUNTING
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 3.
This arrangement allows for
slight shifting of position to
accommodate alignment with
the mounting holes in the
base plate.
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.
Figure 3 –
Pipe Type Anchor Bolt
BOLT
BASE
STANDARD
PIPE
WASHER

105-A00 page 4/12
INSTALLATION
COUPLING ALIGNMENT
The pump must be directly coupled to a gear reducer and/or
driver with a flexible coupling. Both angular and parallel
coupling alignment MUST be maintained between the pump,
gear, motor, etc. in accordance with manufacturer’s
instructions. See Figure 4.
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 .0005" (0.127 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 0.005" (0.127 mm). Some
laser alignment tools will check angular alignment as
well.
3. Replace the coupling guards after setting alignment.
Figure 4 – Coupling Alignment
Do not operate
without guard
in place
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
PUMP ROTATION NOTICE:
CONFIRM CORRECT PUMP ROTATION BY CHECKING
THE PUMP ROTATION ARROWS RESPECTIVE TO PUMP
DRIVER ROTATION.
TO CHANGE 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.
OPERATION
Do not operate
without guard
in place
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
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
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
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. 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.
3. Install suction and discharge pressure gauges on the
pump in the threaded connections provided. These can be
used to check actual suction and discharge conditions
after pump start-up.
4. Check the wiring of the motor.
5. Briefly start the pump to verify proper rotation direction.

105-A00 Page 5/12
OPERATION
START UP PROCEDURES
NOTICE:
CONSULT THE "GENERAL PUMP TROUBLESHOOTING"
SECTION OF THIS MANUAL IF DIFFICULTIES DURING
START UP ARE EXPERIENCED.
1. Start the pump. Priming should occur within one minute.
2. Check the suction and discharge pressure gauges to see
if the pump is operating within the expected conditions.
3. Check for leakage from the piping and equipment.
4. Check for excessive noise, vibration or overheating of the
pump, reducer, and motor.
5. If possible, check the flow rate.
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.
CAUTION: 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."
Hazardous pressure
can cause personal
injury or property
damage
INCORRECT SETTINGS OF THE
PRESSURE RELIEF VALVE CAN CAUSE
PUMP COMPONENT FAILURE,
PERSONAL INJURY, AND 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. 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.
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.
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.
Hazardous pressure
can cause personal
injury or property
damage
INCORRECT SETTINGS OF THE
PRESSURE RELIEF VALVE CAN CAUSE
PUMP COMPONENT FAILURE,
PERSONAL INJURY, AND PROPERTY
DAMAGE.
Hazardous or toxic
fluids can cause
serious injury.
RELIEF VALVE CAP IS EXPOSED TO
PUMPAGE AND WILL CONTAIN SOME
FLUID

105-A00 Page 6/12
MAINTENANCE
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 DISCONNECT AND
LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING MAINTENANCE
CAN CAUSE SHOCK, BURNS OR
DEATH
Hazardous pressure
can cause personal
injury or property
dama
g
e
DISCONNECTING FLUID OR
PRESSURE CONTAINMENT
COMPONENTS DURING PUMP
OPERATION CAN CAUSE SERIOUS
PERSONAL INJURY, DEATH OR
MAJOR PROPERTY DAMAGE.. Do not operate
without guard
in place
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
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 or toxic
fluids can cause
serious injury.
IF PUMPING HAZARDOUS OR TOXIC
FLUIDS, SYSTEM MUST BE FLUSHED
AND DECONTAMINATED, INSIDE AND
OUT, PRIOR TO PERFORMING SERVICE
OR MAINTENANCE
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY. FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL.
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.
Pump bearings should be lubricated every one to twelve weeks
(AT MINIMUM), depending on the application, and operating
conditions.
Recommended Grease:
Exxon® - RONNEX MP Grease,
Mobile® - MOBILITH AW-2 (64353-6) Grease, 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. (76)
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.

105-A00 Page 7/12
MAINTENANCE
VANE REPLACEMENT
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
TECHNICIANS ONLY. FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN
MANUAL.
1. Relieve pressure, drain and flush the pump and system
as required.
2. Remove the head assembly from the outboard (non-
driven) side of the pump according to steps 4 - 9 in the
"Pump Disassembly" section of this manual.
3. Turn the shaft by hand until a vane (14) comes to the top
(12 o'clock) position of the rotor. Remove the vane.
4. Install a new vane (14), ensuring that the rounded edge
is UP, and the relief grooves are facing towards the
direction of rotation. See Figure 5.
5. Repeat steps 3 and 4 until all vanes have been replaced.
NOTE: The standard rotor & shaft has eight vanes and
no push rods. The optional rotor & shaft has four vanes
and two push rods.
6. Reassemble the pump according to the "Pump
Assembly." section of this manual.
ROUNDED EDGE OUT
RELIEF GROOVES
FACE IN DIRECTION
OF ROTATION
Figure 5 – 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. Relieve pressure, drain and flush 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 (27) and gasket (26) off
the shaft. Discard the bearing cover gasket.
NOTE: On flange mounted pumps, a bracket mount
(108) takes the place of the inboard bearing cover. To
disassemble, take apart the coupling (34) and remove
the mounting screws (28A). The bracket and gasket (26)
can then be removed from the head (20).
4. Remove the outboard bearing cover capscrews (28) and
slide the outboard bearing cover (27A) 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 (24B) 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). Each head (20) has a
threaded jackscrew hole to facilitate removal. Insert a
capscrew (21) into the jackscrew hole to easily remove
head from the casing (12). NOTE: It is a good practice to
attach pump heads to the same ends they were
removed from.
7. Slide the head (20) off the shaft. The bearing (24),
mechanical seal stationary seat and stationary O-ring
(153A & 153D) will come off with the head assembly.
a. Pull the bearing (24) from the housing in the head.
b. 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. Carefully pull the rotating seal assembly, consisting of seal
jacket (153C), rotating seal face and rotating O-ring (153B
& 153E) from the shaft. Remove and discard the rotating
O-ring (153E).
9. Carefully remove the disc (71) and head O-ring (72).
10. Pull the rotor and shaft (13) from the casing (12). While one
hand is pulling the shaft, the other hand should be cupped
underneath the rotor to prevent the vanes (14) from falling
out. Carefully set the rotor and shaft (13) aside for future
vane replacement and reassembly.
11. Lay the pump flat with the remaining head facing upward to
remove the head assembly, mechanical seal, and disc from
the outboard side of the pump, as instructed in steps 6 - 9
above.
12. 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 (12).
PARTS REPLACEMENT
1. If any of the O-rings have been removed or disturbed
during disassembly, they be replaced with new O-rings.
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.

105-A00 Page 8/12
MAINTENANCE
PUMP ASSEMBLY
Before reassembling the pump, inspect all component
parts for wear or damage, and replace as required.
Wash out the bearing/seal recess of the head and
remove any burrs or nicks from the rotor and shaft.
Remove any burrs from the liner.
Reassemble the OUTBOARD side of the pump first:
1. Align the liner keyway with the setscrew (74) that
extends down into the pump casing (12) and start the
liner (41) 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. Place the disc (71) against the liner (41) with the seal
cavity outward and disc relief hole located as shown in
Figure 6.
3. Without installing the head O-ring (72) or mechanical
seal components, temporarily attach the outboard head
(20) and bearing (24) to the casing (12). Install and
hand-tighten two head capscrews (21), 180 degrees
apart. This head will be used to hold and align the rotor
and shaft (13) while the inboard side of the pump is
assembled. NOTE: It is a good practice to attach
pump heads to the same ends they were removed
from.
4. Before installing the rotor & shaft assembly (13), the
direction of pump rotation must be determined as
follows: If the pump is to be right-hand with clockwise
rotation, the intake port and the relief valve must be on
the right with the drive end of the shaft pointing towards
the observer. If the pump is to be left-hand with
counterclockwise rotation, the intake port and the relief
valve must be on the left with the drive end of the shaft
pointing towards the observer.
5. Remove the vanes (14) and push rods (77) (if equipped)
from the rotor and shaft assembly (13). Inspect for wear
and damage, and replace as follows:
a. Insert the vanes (14) into the bottom rotor slots with
the relief grooves facing in the direction of pump
rotation, and with the rounded edges outward. See
Figure 5.
Figure 6 - Disc Relief Hole Location
b. If the pump is equipped with the four-vane rotor and
shaft (13A), hold the two bottom vanes (14) in place
while inserting the two push rods (77).
c. After the bottom vanes (14) (and push rods, (77) if
equipped) are installed, carefully insert the non-driven
end of rotor and shaft into the casing (12).
d. Install all remaining vanes (14) into the top positions of
the rotor.
6. 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.
7. Install a new head O-ring (72) in the groove between the
disc (71) and the casing(12).
8. MECHANICAL SEAL INSTALLATION
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 –
d. Apply a small amount of motor oil in the seal recess of
the head (20).
e. 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. Carefully install the inboard head assembly (20) over the
shaft. Do not contact the end of the shaft with the polished
face of the stationary seat. Center the head on the pump
casing (12). Install and uniformly tighten four head
capscrews (21) 90° apart,; torque to 15 lbs ft (20.3 Nm).
NOTE: It is a good practice to attach pump heads to
the same ends they were removed from.
10. Hand pack the ball bearing (24) with grease. Refer to the
"Lubrication" section for the recommended grease.
11. Install the bearing (24) into the head recess. The bearing
balls should face outward, with the grease shield inward.
The bearing must be fully and squarely seated in the head
(20).
12. Turn the pump casing around and remove the outboard
head (20) previously installed.
13. Install the outboard head (20), mechanical seal (153) and
bearing (24) as instructed in steps 6 through 11.
14. 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
(20) with a soft faced mallet until the correct position is
found. Install all of the remaining head capscrews (21) for
each head and uniformly torque to 15 lbs ft (20.3 Nm).

105-A00 Page 9/12
MAINTENANCE
Figure 7 – Locknut Assembly
15. 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 (71), causing wear. See
Figure 7.
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 (24B) to ensure that the
bearings (24) are bottomed in the head recess. DO
NOT overtighten and bend or shear the lockwasher
inner tang.
c. Loosen both locknuts (24A) one complete turn.
d. Tighten one locknut (24A) 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 (24A) by hand until it is
snug against the bearing (24). 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 (.001" - 25
microns). Begin by loosening the locknut (24A)
adjusted last.
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
(27) or bracket mount (108) with the lip of the seal
inward (towards the pump).
17. Attach a new bearing cover gasket (26) and the inboard
bearing cover (27) to the inboard head (20). Install the
outboard bearing cover (27A) 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 8 lbs ft (10.8 Nm).
18. On flange mounted pumps, the bracket mount takes the
place of the inboard bearing cover (27). To attach the
bracket mount to the head, install a new bearing cover
gasket (26) and the four mounting screws (28A).
19. 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"
20. Reinstall coupling, shaft key, and coupling guards.
Do not operate
without guard in
place.
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
21. Refer to “Pre-Start Up Check List” and “Start Up
Procedures” sections of this manual prior to restarting
pump operation.

105-A00 Page 10/12
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. Internal control valve closed.
4. Strainer clogged.
5. Inlet line or valves clogged or too restrictive.
6. Broken drive train (truck mounted pumps).
7. Pump vapor-locked.
8. Pump speed too low for priming.
9. Relief valve partially open, worn or not seating properly.
Reduced Capacity 1. Pump speed too low.
2. Internal control valve not fully open.
3. Excessive restriction in inlet line (undersized piping, too many elbows & fittings, clogged strainer, etc.).
4. Damaged or worn parts (vanes, discs, liner or rotor).
5. Excessive restriction in discharge line causing partial flow through the relief valve.
6. Relief Valve worn, set too low, or not seating properly.
7. External Bypass Valve set too low.
8. Vanes installed incorrectly (see "Vane Replacement").
9. Liner installed backwards
Noise 1. Excessive pressure drop on the pump due to:
a. Undersized or restricted fittings in the inlet line.
b. Pump speed too fast.
c. Pump too far from fluid source.
2. Running the pump for extended periods with a closed discharge line.
3. Pump not securely mounted.
4. Misalignment of pump, reducer or motor - base mounted pumps.
5. Bearings worn or damaged.
6. Vibration from improperly anchored piping.
7. Bent shaft, or drive coupling misaligned.
8. Excessively worn rotor.
9. Malfunctioning valve in the system.
10. Relief valve setting too low.
11. Liner installed backwards.
12. Damaged vanes (see following category).
Damaged Vanes 1. Foreign objects entering the pump.
2. Running the pump dry for extended periods of time.
3. Cavitation.
4. Excessive heat.
5. Worn or bent push rods, or worn push rod holes.
6. Hydraulic hammer - pressure spikes.
7. Vanes installed incorrectly (see"Vane Replacement").
8. Viscosity too high for the vanes and/or the pump speed.
9. Settled or solidified material in the pump at startup.
10. Incompatibility with the liquids pumped.
Broken Shaft 1. Foreign objects entering the pump.
2. Relief valve not opening.
3. Hydraulic hammer - pressure spikes.
4. Pump/driver, driveline/drive shaft misalignment.
5. Viscosity too high for the vanes and/or the pump speed.
6. Settled or solidified material in the pump at startup.
7. Excessively worn vanes or vane slots.
Mechanical Seal Leakage 1. O-rings not compatible with the liquids pumped.
2. O-rings nicked, cut or twisted.
3. Shaft at seal area damaged, worn or dirty.
4. Ball bearings overgreased.
5. Excessive cavitation.
6. Mechanical seal faces cracked, scratched, pitted or dirty.
Overload on Motor 1. Motor Horsepower not sufficient for application.
2. Improper wiring and/or low votage to motor.
3. Misalignment
4. Excessive 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.

105-A00 Page 11/12
NOTES

Sliding Vane Pumps: 5 to 2200 GPM
Refined Fuels, Liquefied Gases, Solvents,Process
Stainless Steel Sliding Vane Pumps
1 to 265 GPM: Acids, Brines, Sugars, Syrups,
Beer, Beet Juice, Cider, Flavor Extracts, etc.
System One®Centrifugal Pumps
10 to 7500 GPM; Process, Marine
Magnetic Drive Pumps
Stainless Steel: 14 to 215 GPM
HXL 6, 8 & 10”
Sliding Vane Pumps
130 to 2,220 GPM
Refineries
Terminals
Barges
Ships
Reciprocating Gas Compressors
Liquefied Gas Transfer, Boosting, Vapor Recovery
Hand Operated Pumps
Dispensing, Transfer, In-line
Accessories
Gear Reducers, Bypass Valves, Strainers
Visit www.blackmer.com for complete information on all Blackmer products
1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A.
Telephone: [phone] • Fax: [phone]
E-mail: black[email protected] • Internet Address: www .blackmer.com