BLACKMER SGLD4A User manual

BLACKMER LIQUEFIED GAS PUMPS 964425
INSTRUCTIONS NO. 801-B00_apr05
FOR LIQUEFIED GAS SERVICE TRUCK AND BASE MOUNTED
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS Section
Effective
Replaces
801
April 2005
Feb 2002
MODELS: SGLD2, SGLD3
Discontinued Models: SGLD4A, SGLD4
TABLE OF CONTENTS Page
SAFETY DATA.....................................................................1
PUMP DATA
Pump Identification.....................................................2
Technical Data...........................................................2
Initial Pump Start Up Information ...............................2
GENERAL INSTALLATION AND OPERATION
Welded Connections..................................................3
Pre-Installation Cleaning............................................3
Location and Piping....................................................3
Pump Relief Valve and Bypass Valve........................4
Relief Valve Setting and Adjustment..........................4
Check Valves.............................................................4
Pump Rotation ...........................................................4
MOTOR DRIVEN PUMPS
Pump Mounting..........................................................5
Coupling Alignment....................................................5
V-Belt Drive................................................................5
V-Belt Disassembly....................................................6
Pre-Start Up Check List .............................................6
Start Up Procedures...................................................6
TRUCK MOUNTED PUMPS
Truck Mounting ..........................................................7
Pump Drive ................................................................7
Hydraulic Drive...........................................................7
Pre-Start Up Check List .............................................8
Start Up Procedures...................................................8
Pump Speed ..............................................................8
MAINTENANCE
Strainers.....................................................................9
Lubrication..................................................................9
Vane Replacement...................................................10
Pump Disassembly ..................................................10
Pump Assembly.......................................................11
TROUBLE SHOOTING ......................................................14
NOTE: Numbers in parentheses following individual parts
indicate reference numbers on Blackmer Parts Lists 801-B01
and 801-B02.
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 liquefied gas 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 liquefied gas pumps,
and MUST be kept with the pump.
Blackmer liquefied gas 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 liquefied gas pumps.
Maintain ALL system and Blackmer liquefied gas
pump operation and hazard warning decals.
Aug 2007: SGLD4A discontinued

801-B00 Page 2/16
SAFETY DATA
Hazardous
machinery can
cause serious
personal injury.
FAILURE TO SET THE VEHICLE
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING
SERVICE CAN CAUSE SEVERE
PERSONAL INJURY OR PROPERTY
DAMAGE 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
machinery can
cause serious
personal injury.
FAILURE TO DISCONNECT AND
LOCKOUT ELECTRICAL POWER OR
ENGINE DRIVE BEFORE ATTEMPTING
MAINTENANCE CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH 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 serious
personal injury or
property damage
DISCONNECTING FLUID OR PRESSURE
CONTAINMENT COMPONENTS DURING
PUMP OPERATION CAN CAUSE
SERIOUS PERSONAL INJURY OR
PROPERTY DAMAGE. Hazardous pressure
can cause serious
personal injury or
property damage
FAILURE TO RELIEVE SYSTEM
PRESSURE PRIOR TO PERFORMING
PUMP SERVICE CAN CAUSE SERIOUS
PERSONAL INJURY OR PROPERTY
DAMAGE. SYSTEMS WITH METERS
WILL STILL BE PRESSURIZED EVEN
AFTER THE HOSE IS EMPTIED
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
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 Operating Temperature 240°F (115°C)
Minimum Operating Temperature -30°F (-34°C)
Maximum Pump Speed 640 RPM
Maximum Differential Pressure
2” and 3” models
4” models
150 PSI (10.3 Bar)
125 PSI (8.6 Bar)
Maximum Working Pressure 525 PSI (36.2 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: _____________________________________

801-B00 Page 3/16
GENERAL INSTALLATION AND OPERATION
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.
WELDED CONNECTIONS
NOTICE:
PUMPS WITH WELDED CONNECTIONS CONTAIN THREE
NON-METALLIC O-RING SEALS THAT WILL BE
DAMAGED IF WELDING IS DONE WITH THESE O-RINGS
INSTALLED.
Prior to welding the piping, remove the O-rings from under the
inlet flange, outlet flange and relief valve cover as indicated in
Figure 1.
Reinstall the inlet and outlet flanges. Weld the piping to the
the inlet and outlet flanges. After the welding is complete,
reinstall the O-rings.
Figure 1
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:
1. Locate the pump as near as possible to the source of
supply to avoid excessive inlet pipe friction.
2. The inlet piping and fittings 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.
Minimize the number of intake line fittings and 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. ALL piping and fittings MUST be properly supported to
prevent any piping loads from being placed on the pump.
7. 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
8. Install pressure gauges in the NPT ports provided in the
pump casing to check pump performance at start up.
9. The use of a vapor return line will speed up delivery by
preventing pressure build up at the receiving tank and
reducing pressure in the supply tank.
10. Keeping the liquefied gas systems full of liquid, even
when idle, will keep the O-rings from changing shape,
shrinking or super cooling. Evaporation of liquefied gas
leaves an abrasive powder on the surface which can
cause wear to the pump, meter, and seals.

801-B00 Page 4/16
GENERAL INSTALLATION AND OPERATION
INTERNAL PUMP RELIEF VALVE AND
EXTERNAL BYPASS 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.
For ALL liquefied gas applications, install an external bypass
valve, and any necessary piping, back to the tank. DO NOT
pipe the bypass valve back to the intake line. The setting on
the external bypass valve must be at least 25 psi (1.7 bar)
lower than the pump internal relief valve setting. The valve
and piping must be of adequate size to accommodate the full
flow from the pump when the discharge line is closed. The
non-adjustable pump internal relief valve is factory set at
approximately 125 PSI (8.6 bar).
Refer to Blackmer Bypass Valve Installation and Maintenance
Instructions for bypass valve settings and adjustments.
Figure 3 – Bypass Valve Mounting
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 and O-
ring.
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 and O-ring.
Refer to the individual Blackmer pump parts lists for various
spring pressure ranges.
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
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 ROTATIONNOTICE:
CONFIRM CORRECT PUMP ROTATION BY CHECKING
THE PUMP ROTATION ARROWS RESPECTIVE TO PUMP
DRIVER ROTATION.
Blackmer SGL pumps have a double ended rotor and shaft,
enabling them to be driven from either shaft end. To change
rotation, rotate the pump 180 degrees so that the opposite
shaft becomes the driven shaft. The shaft protector (186)
MUST be mounted over the non-driven shaft.
Do not operate
without guard
in place
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.

801-B00 Page 5/16
MOTOR DRIVEN PUMPS - INSTALLATION AND OPERATION
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.
NOTICE:
CONSULT THE "GENERAL INSTALLATION AND
OPERATION" SECTION OF THIS MANUAL FOR SYSTEM
INFORMATION.
PUMP MOUNTING
Permanently mount the unit by securing the base plate with
adequately sized anchor bolts to a level concrete floor
following recommended industry standards (See Figure 4). 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.
BOLT
BASE
STANDARD
PIPE
WASHER
Figure 4
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 5.
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 also check angular alignment.
3. Replace the coupling guards after setting alignment.
Figure 5 – Coupling Alignment
Do not operate
without guard
in place
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
V-BELT DRIVE
For installation of Blackmer V-belt units, first mount the pump
and the motor base to the unit base. Do not fully tighten the
motor mounting bolts until properly installing and adjusting the
belts as follows:
1. Wipe the cone surface of the pump QD hub (152A) and
the inside of the pump sheave hub with a clean cloth
moistened with a light grade of machine oil. This will
allow for a more uniform draw and prevent the cone
surfaces from “freezing” before being tightened.
2. With the pump shaft key (35) in place, align the key seat
and slide the QD hub (152A) on the shaft, flange end
first. Slide the large end of the sheave (152) bore over
the taper on the QD hub. Insert the three sheave
capscrews (152G) through the clearance holes in the
sheave, and start them into the tapped holes of the QD
hub (152A). Repeat this procedure to assemble the
motor QD hub (152E) and sheave (152D).
3. To install the belts (181), shorten the center distance of
the drive by moving the motor towards the pump, until the
belts can be put on the sheaves (152 & 152D) without
forcing.
4. Align the sheaves so that the faces are parallel, then
snug up the sheave capscrews (152C & G).
5. Measure the span length as shown in Figure 6.
Figure 6 - V-Belt Adjustment

801-B00 Page 6/16
MOTOR DRIVEN PUMPS - INSTALLATION AND OPERATION
V-BELT DRIVE …. Continued
6. Adjust the motor base (183) and apply a specified force
(see Table 1) against the belt, at the center of the span,
so that the belt is deflected 1/64 inch (0.04 mm) for every
inch (25.4 mm) of span. For example, the deflection of a
20 inch (508 mm) span would be 20/64 or 5/16 inch (7.9
mm). The force required should be within the range given
in Table 1 for a properly tensioned drive. A new set of
belts should be initially tensioned to the upper limit.
BELT DEFLECTION FORCE
SMALL SHEAVE
OUTSIDE DIAMETER Minimum Maximum
2.5” to 4.5”
(63 mm to 114 mm) 3.0 lbs (1.4 kgs) 4.75 lbs (2.2 kgs)
4.75” to 7.0”
(121 mm to 178 mm) 4.0 lbs (1.8 kgs) 6.0 lbs (2.7 kgs)
Table 1 - Deflection Force Per Belt
7. Check again to ensure the sheaves (152 & 152D) are
parallel, then tighten the sheave capscrews (152C &
152G), the motor mounting nuts (183B) and the adjusting
screw locknut (183B).
8. Assemble the belt guard (182) and the belt guard brace
(182A) to the unit base (32).
Do not operate
without guard
in place
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
9. Check the belt tension after 24-48 hours of operating.
Recheck the tension periodically and tighten the belts as
required. DO NOT overtighten belts. Inspect belts
periodically for signs of excessive wear, and replace as
required.
V-BELT DISASSEMBLY
1. Remove the belt guard (182) and the guard base (182A).
Loosen the adjusting screw locknut (183B) on the motor
base (183) and the motor mounting nuts.
2. Ease the tension on the belts (181) by moving the motor
towards the pump to shorten the center distance of the
drive. Remove the belts by sliding them over the sheaves
(152 & 152D). DO NOT force the belts over the grooves.
3. To remove the sheave from the hub, first remove the
three sheave capscrews (152C or 152G). Then screw
two of the capscrews into the threaded holes in the
sheave hub (152A or E). If the cone grip is hard to break
loose, tap the end of the shaft or the QD hub with soft-
faced mallet while maintaining pressure on the screw.
4. The QD hub should slide smoothly off the shaft. If it is tight
on the shaft, gently pry it loose with a screwdriver or a small
wedge placed in the split part of the flange.
Refer to Blackmer V-Belt Parts List and Instructions for V-belt
drive and guard part numbers.
PRE-START UP CHECK LIST
1. Inspect complete piping system and supports to ensure
that no piping loads are being placed on the pump.
2. Install pressure gauges in the 1/4" NPT intake and
discharge ports located on the pump casing to check
pump performance after start-up.
3. Ensure all valves and fittings in piping system are in the
start-up or operating positions.
4. Jog the pump motor to verify proper pump rotation.
START UP PROCEDURES
NOTICE:
CONSULT THE "TROUBLESHOOTING" SECTIONS OF
THIS MANUAL IF DIFFICULTIES DURING START UP ARE
EXPERIENCED.
1. SLOWLY build pressure in the pump.
2. Start the motor.
3. Check 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 for future reference.
4. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
5. Check the flow rate to ensure the pump is operating
within the expected parameters. Record flow rate in the
“Initial Start Up” section of this manual.
6. Close the discharge valve and check the differential
pressure across the pump. Pressure must not exceed the
pressure setting of the external bypass valve.
7. With the discharge valve still closed, momentarily close
the manual shut-off valve in the bypass return line to
check the pump internal relief valve. The differential
pressure will be approximately 150 and 170 PSI (10.3
and 11.7 bar).
8. The external bypass valve must always be set at least 25
PSI (1.7 bar) lower than the internal pump relief valve.
NOTE: The normal operating pressure must be at least 5
- 15 PSI (0.3 -1.0 bar) less than the external bypass
valve setting. Pump speeds which result in higher
pressures (nearing the valve setting) forces the liquid to
recirculate, creating excessive wear on the pump and
equipment.
Hazardous pressure
can cause personal
injury or property
damage
PUMPS OPERATING AGAINST A
CLOSED VALVE CAN CAUSE SYSTEM
FAILURE, PERSONAL INJURY AND
PROPERTY DAMAGE

801-B00 Page 7/16
TRUCK MOUNTED PUMPS - INSTALLATION AND OPERATION
Hazardous pressure
can cause personal
injury or property
damage
FAILURE TO SET THE VEHICLE
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING
SERVICE CAN CAUSE SEVERE
PERSONAL INJURY OR PROPERTY
DAMAGE.
NOTICE:
CONSULT THE "GENERAL INSTALLATION AND
OPERATION" SECTION OF THIS MANUAL FOR SYSTEM
INFORMATION.
TRUCK MOUNTING
SGL pumps can be bolted to the truck frame or on a saddle
hung below the frame, and MUST be adequately supported.
PUMP DRIVE
The pump may be driven by a power take-off through
universal joints. When using universal joints, a splined slip
joint, properly lubricated, must be used on the connecting jack
shaft to prevent end thrust on the pump shaft. It is very
important to install a proper drive line to avoid excessive
wear, vibration and noise (see Fig. 7 and Table 2).
General guidelines to follow for proper pump drive:
1. Do not use square slip joints.
2. Use the least number of jack shafts as is practical.
3. Use an even number of universal joints.
4. The pump shaft and power take-off shaft must be parallel
in all respects. Use an angular level measuring device to
ensure the PTO and pump shaft are parallel to each
other. If necessary, the pump can be shimmed to correct
any misalignment. The PTO shaft coming off at the trans-
mission does not need to be perfectly horizontal as long
as the pump is shimmed to have its shaft parallel in all
respects to the PTO shaft.
5. The yokes of the universals at both ends of the jack shaft
must be parallel and in phase.
6. The maximum recommended angle between the jack
shaft and the pump shaft is 15 degrees. See Table 2.
Failure to follow any of these guidelines may result in a gallop
or uneven turning of the pump rotor, which will in turn cause a
surging vibration to the liquid stream and piping system.
Contact the supplier of the drive line components for specific
design assistance.
Do not operate
without guard
in place
A DRIVE SHAFT GUARD BETWEEN THE
PTO AND PUMP MUST BE PROVIDED
TO PREVENT PERSONAL INJURY,
PROPERTY DAMAGE, OR DEATH.
Note: A Drive Shaft Guard between the pump and the PTO
MUST be provided. (Not Shown)
Figure 7 – Pump Drive
Angle of Drive Shaft
1° through 5° 6° through 10° 11° through 15°
Very good Good Fair
Table 2
HYDRAULIC DRIVE
Truck mounted pumps may also be driven hydraulically.
Hydraulic motors should be well supported with their shafts
parallel to the pump shaft in all respects. Blackmer provides
an optional close-coupled hydraulic motor adapter. The
adapter provides for straight alignment of a hydraulic motor
drive through a solid coupling connected to a straight key
pump shaft. This coupling connection requires grease
lubrication every three months at minimum. See the
"Lubrication" section of this manual.
Do not operate
without guard
in place
OPERATION WITHOUT SHAFT
PROTECTOR CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.

801-B00 Page 8/16
TRUCK MOUNTED PUMPS - INSTALLATION AND OPERATION
PRE-START UP CHECK LIST
1. Install pressure gauges in the 1/4" NPT ports located on
the pump casing. These can be used to check the actual
inlet and discharge conditions after pump start-up.
2. Check the alignment of the pipes to the pump. Pipes
must be supported so that they do not spring away or drop
down when the pump flanges or union joints are
disconnected.
3. Secure appropriate hose connections.
START UP PROCEDURES
NOTICE:
CONSULT THE "GENERAL PUMP TROUBLESHOOTING"
SECTION OF THIS MANUAL IF DIFFICULTIES DURING
START UP ARE EXPERIENCED.
Hazardous pressure
can cause personal
injury or property
damage
PUMPS OPERATING AGAINST A
CLOSED VALVE CAN CAUSE SYSTEM
FAILURE, PERSONAL INJURY AND
PROPERTY DAMAGE
1. Open the shut-off valve in the bypass return line.
2. If the tank outlet valve is:
a. Lever Operated - Pull the control knob all the way
out. Manually check the lever under the truck to see
that it is in the completely OPEN position.
b. Discharge Pressure Operated - Keep the discharge
line valve closed. When pump is started, it will build up
enough pressure to open the tank outlet valve. NOTE:
This type of valve usually requires approximately 20
PSI (1.4 bar) differential pressure to open and
approximately 15 PSI (1.0 bar) differential pressure to
keep it open. If the piping is quite large, it may be
necessary to restrict the discharge line shut-off valve
in order to maintain sufficient pressure to keep the
tank outlet valve open.
3. Start the pump. Confirm proper pump rotation by checking
the pump rotation arrows.
4. Check the pump speed. Pump speed must never exceed
the recommended maximum. See “Technical Data” section
of this manual.
5. Check the 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 for future reference.
6. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
7. Check the flow rate to ensure the pump is operating within
the expected parameters. Record the flow rate in the “Initial
Start Up Information” section of this manual for future
reference.
8. Close the discharge valve and check the differential
pressure across the pump. It must not exceed the pressure
setting of the external bypass valve.
9. With the discharge valve still closed, momentarily close the
manual shut-off valve in the bypass return line to check the
internal pump relief valve. The differential pressure should
be about 100 PSI (6.9 bar).
10. The external bypass valve must always be set at least 25
PSI (1.7 bar) lower than the pump internal relief valve.
NOTE: The normal operating pressure must be at least 5 -
15 PSI (0.3 - 1.0 bar) less than the external bypass valve
setting. Pump speeds which result in higher pressures
(nearing the valve setting) forces the liquid to be
recirculated, creating excessive wear on the pump and
equipment.
PUMP SPEED
PTO and hydraulically driven units MUST contain speed
control devices to prevent pump speeds above the maximum
RPM specifications, regardless of the truck engine unloading
speeds. Should fluid delivery be appreciably less than
expected, see the "Troubleshooting" section.

801-B00 Page 9/16
MAINTENANCE
Hazardous
machinery can
cause serious
personal injury.
FAILURE TO SET THE VEHICLE
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING
SERVICE CAN CAUSE SEVERE
PERSONAL INJURY OR PROPERTY
DAMAGE 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
machinery can
cause serious
personal injury.
FAILURE TO DISCONNECT AND
LOCKOUT ELECTRICAL POWER OR
ENGINE DRIVE BEFORE ATTEMPTING
MAINTENANCE CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH 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 OR
PROPERTY DAMAGE. Hazardous pressure
can cause serious
personal injury or
property damage
FAILURE TO RELIEVE SYSTEM
PRESSURE PRIOR TO PERFORMING
PUMP SERVICE CAN CAUSE SERIOUS
PERSONAL INJURY OR PROPERTY
DAMAGE. SYSTEMS WITH METERS
WILL STILL BE PRESSURIZED EVEN
AFTER THE HOSE IS EMPTIED
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.
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,
HYDRAULIC ADAPTER COUPLING, GEAR REDUCER
OR ANY OTHER PARTS WHILE PUMP IS RUNNING
Pump bearings and hydraulic motor couplings (if equipped)
must be lubricated every three months at a minimum. More
frequent lubrication may be required, depending on the
application and the operating conditions.
Recommended Grease:
Exxon® - Ronnex MP Grease
Mobil® - Mobilith AW2 (64353-6) Grease, or equivalent Lithium
grease.
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
covers (27) or hydraulic motor adapter (135).
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 the proper codes and
regulations.
3. Replace the grease relief fittings (76A).
DO NOT over grease 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 (20) between
the bearing (24) and the mechanical seal (153).

801-B00 Page 10/16
MAINTENANCE
VANE REPLACEMENT
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN THIS
MANUAL.
1. Drain and relieve pressure from the pump and system as
required.
2. Remove the head assembly from the outboard (non-
driven) side of the pump according to steps 4 - 7 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 8.
5. Repeat steps 3 and 4 until all vanes have been replaced.
6. Reassemble the pump according to the "Pump
Assembly." section of this manual.
Figure 8 – Vane Installation
PUMP DISASSEMBLY
NOTICE:
FOLLOW ALL HAZARD WARNINGS AND INSTRUCTIONS
PROVIDED IN THE "MAINTENANCE" SECTION OF THIS
MANUAL.
1. 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 (27) and gasket (26) off
the shaft. Discard the bearing cover gasket. On 2-inch
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 (24A) 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) and carefully pry the
head (20) away from the casing (12).
7. Slide the head (20) off the shaft. The head O-ring (72),
bearing (24), mechanical seal stationary seat and
stationary O-ring (153A & 153D) will come off with the
head assembly. Remove and discard the head O-ring. On
4-inch models, the disc and rotating seal assembly will
also come off with the head assembly.
a. 4-inch models: Remove the four disc machine
screws and lockwashers (71A & 71B) to release the
disc (71) from the head (20). 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
(20).
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. 2 and 3-inch models: Carefully pull the rotating seal
assembly, including the seal jacket, rotating seal face and
O-ring (153C, 153B, 153E) from the shaft. Remove and
discard the rotating O-ring. Remove the disc (71).
9. Carefully pull the rotor and shaft (13) from the casing (12).
While one hand is pulling the shaft, cup the other hand
underneath the rotor to prevent the vanes (14) and push
rods (77) from falling out. Carefully set the rotor and shaft
aside for future vane replacement and reassembly.
NOTICE:
The rotor and shaft weighs 34 - 69 pounds (15 -
31 kg). Be careful not to pinch the hand under
the rotor and shaft when removing from
casing.
10. Lay the pump flat with the remaining head (20) facing
upward to remove the head assembly mechanical seal
(153) and disc (71) from the outboard side of the pump,
per steps 6 - 8 above.
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 (12).

801-B00 Page 11/16
MAINTENANCE
PUMP ASSEMBLY
Before reassembling the pump, inspect all component parts
for wear or damage; replace as required. Wash out the
bearing/seal recess of the head and remove any burrs or
nicks from the rotor and shaft, and liner.
Reassemble the OUTBOARD side of the pump first:
1. Apply a small amount of grease to the liner key (74) to
hold the key in place during liner installation. Install the
liner key (74) in the groove on top of the liner (41).
2. Align the liner key (74) with the pump casing keyway and
start the liner (41) into the casing (12). 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. NOTE:
If the liner is installed backwards, it will restrict the port
openings and cause cavitation, noise and loss of
capacity.
3. 2 and 3-inch models: Place the disc (71) against the liner
with the seal cavity outward.
4. 4-inch models: Attach the disc (71) to the outboard head
without the mechanical seal components. Install the disc
machine screws (71A) and lockwashers (71B).
5. Without installing 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.
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 8.
b. Hold the three bottom vanes I place while inserting
the three push rods (77). See Figure 9.
c. Carefully insert the non-driven end of the rotor and
shaft (13) into the pump casing (12).
d. Install the remaining vanes (14) into the top positions
of the rotor.
Figure 9 – Pushrod Installation
7. DISC – 2 and 3-inch pumps
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 10.
Figure 10 - Disc Relief Hole Location (2 and 3” pumps)
8. MECHANICAL SEAL – 2 and 3-inch pumps
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 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 recess
of the head (20).
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.
9. MECHANICAL SEAL – 4-inch pumps
Stationary Seat -
a. Apply a small amount of motor oil in the seal recess
of the head (20).
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.
Rotating Assembly –
a. 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 recess.
b. Align the seal jacket assembly (153C) with notches
of the rotating face and install jacket with the drive
tangs of the jacket outward.

801-B00 Page 12/16
MAINTENANCE
10. DISC – 4-inch pumps
Place the disc (71) against the head (20) with the seal
cavity inward and the disc relief hole located so that when
the head is mounted on the pump with the “Blackmer”
name in an upright position, the disc relief hole will be at
the pump intake, (see Figure 11). Install and tighten the
disc machine screws and lockwashers (71A and 71B).
The drive tangs of the seal jacket should protrude through
the center hole of the disc.
Figure 11 - Disc Relief Hole Location (4” pumps”
11. Install a new head O-ring (72) in the groove on the inside
face of the head (20). Lay the O-ring flat and start in on
one side of the groove, stretching ahead with the fingers,
as shown in Figure 12.
Figure 12 – Head O-ring Installation
12. Carefully install the head assembly (20) on the pump
casing (12). Rotate the head so that the drain hole,
located at the back of the bearing cavity, faces downward
when the pump is mounted for operation. Install and
uniformly tighten four head capscrews (21) 90°apart;
torque to 30 lbs ft (40.7 Nm).
4-inch pumps: 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.
13. Hand pack the ball bearing (24) with grease. See the
"Lubrication" section for recommended greases.
14. Install the bearing (24) into the head recess. The bearing
balls should face outward, with the grease shield inward.
Ensure the bearing is fully and squarely seated in the
head (20).
15. Turn the pump casing around and remove the outboard
head and disc previously installed.
16. Install the outboard head, O-ring (72), mechanical seal
(153), disc (71) and bearing (24) per steps 7 through 14.
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.
Install the remaining head capscrews (21) for each head
(20) and uniformly torque to 30 lbs ft (40.7 Nm).
18. 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 (71), causing wear. See Figure 13.
Figure 13 - Locknut Adjustment
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 (24A) 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 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 (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. 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 adjusted last.
19. 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) with the lip of the seal inward.

801-B00 Page 13/16
MAINTENANCE
20. Attach a new bearing cover gasket (26) and the bearing
cover (27) to the inboard head (20). Make sure the
grease fittings (76) are accessible. Install and torque the
bearing cover capscrews (28) to 30 lbs ft (40.7 Nm).
21. Install the grease seal (104) and bearing cover (27) on
the opposite side of the pump per steps 19 - 20.
22. 2-inch pumps: Slide the dirt shield (123A) over the shaft
and push it firmly against the inboard bearing cover.
23. Attach the shaft protector (186) to the non-driven shaft
end of double ended pumps.
Do not operate
without guard
in place
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
24. RELIEF VALVE ASSEMBLY
a. Insert the valve (9) into the relief valve bore of the
casing with the fluted end (2 and 3-inch pumps) or
stepped bore end (4” pumps) 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"
25. See "Pre-Start Up Check List" and "Start Up Procedures"
sections of this manual prior to restarting pump
operation.

801-B00 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. Internal control valve closed.
4. Strainer clogged.
5. Inlet line or valves clogged or too restrictive.
6. Broken Drive Train (truck mounted pumps)7
7. Pump vapor-locked.
8. Pump speed too low for priming.
9. Relief valve partially open, worn or not seating properly.
10. Vanes installed incorrectly (see "Vane Replacement").
Reduced Capacity 1. Pump speed too low.
2. Internal control valve not fully open.
3. Excessive restriction in the inlet line (i.e.: undersized piping, too many elbows & fittings,
clogged strainer, etc.).
4. Damaged or worn parts (vanes, cylinder, or rotor).
5. Excessive restriction in discharge line causing partial flow through the relief valve.
6. Relief Valve worn, set too low, or not seating properly.
7. External Bypass Valve set too low.
8. Operating without a vapor return line.
9. Vanes installed incorrectly (see "Vane Replacement").
10. Liner installed backwards.
Noise 1. Excessive pressure drop 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. Improper drive line – truck mounted pumps (See “Pump Drive”).
5. Misalignment of pump, reducer, or motor - base mounted pumps.
6. Bearings worn or damaged.
7. Vibration from improperly anchored piping.
8. Bent shaft, or drive coupling misaligned.
9. Excessively worn rotor.
10. Malfunctioning valve in the system.
11. Relief valve setting too low.
12. Liner installed backwards.
13. Damaged vanes (see following category).
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. Incompatibility with the liquids pumped.

801-B00 Page 15/16
TROUBLESHOOTING … continued
SYMPTOM PROBABLE CAUSE
Broken Shaft 1. Foreign objects entering the pump.
2. Relief valve not opening.
3. Hydraulic hammer - pressure spikes.
4. Pump/driver, driveline/drive shaft misalignment.
5. Excessively worn vanes or vane slots.
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. 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 voltage to motor.
3. Misalignment
4. Excessive pressure or speed.
5. Bearing locknuts adjusted improperly.
6. Faulty or worn bearings.
7. Rotor rubbing against discs or liner.
8. Dirty mechanical seal faces.

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