Dover PCG Blackmer XRLF1.25B Manual

BLACKMER POWER PUMPS 960207
INSTRUCTIONS NO. 107-A00
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS Section
Effective
Replaces
107
Aug 2014
Jan 2014
MODELS: XRLF1.25B, XRL1.25A, XLF1.25B, XL1.25A, XLF1.5B, XL1.5A
Discontinued: XRLF1¼(A), XLRL1¼, XLF1¼(A), XL1¼, XLF1½(A), XL1½
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
Motor Adaptors....................................................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.
107-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.

107-A00 page 2/12
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
Maximum Pump Speed 1,750 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: _____________________________________
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.

107-A00 page 3/12
INSTALLATION
PRE-INSTALLATION CLEANING
NOTICE:
This pump contains some 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 pipe and fittings should be at least as large as
the intake port on the pump. Slope the pipe downward to
the pump, and do not install 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. Locate the strainer at least 24"
(0.6m) from the pump. Strainers must have a net open
area of at least four times the area of the intake piping,
and 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. Install pressure gauges in the NPT ports provided in the
pump casing to check pump performance at startup.
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 must 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, make
provisions 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. Use shims under the edges of the
base prior to tightening of the anchor bolts to prevent
distortion.
MOTOR ADAPTORS
‘XLF’ and ‘XRLF’ models are fitted with a motor adaptor to
provide direct mounting to flange faced motors. NEMA motor
adaptors are available in unfooted and footed styles for a
range of motor sizes. IEC motor adaptors are unfooted.
Unfooted motor adaptors require footed motors.
Footed motor adaptors should be used with unfooted motors
when available. If a footed motor is used, the motor must not
be secured to baseplate.
Figure 3 –
Pipe Type Anchor Bolt
BOLT
BASE
STANDARD
PIPE
WASHER

107-A00 page 4/12
INSTALLATION
COUPLING ALIGNMENT
The pump must be directly coupled to a gear reducer 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 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 must be less than
0.005" (0.127 mm).
2. Angular alignment: Insert a feeler gauge between the
coupling halves. Check the spacing at 90° increments
around the coupling (four checkpoints). Maximum
variation must 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
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard
in place
PUMP ROTATIONNOTICE:
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
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
must be supported so that they do not spring away or
drop down when pump flanges or union joints are
disconnected.
2. Verify proper coupling alignment.
3. 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.
4. 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.
5. Check the wiring of the motor.
6. Briefly start the pump to verify proper rotation direction.

107-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."
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
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.
XL 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.
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.

107-A00 Page 6/12
MAINTENANCE
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
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.
Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury, death or major property
damage.
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
dama
g
e Hazardous or toxic
fluids can cause
serious injury.
Failure to relieve system pressure prior
to performing pump service or
maintenance can cause personal injury
or property damage.
NOTICE:
Maintenance shall be performed by qualified
technicians only. Follow the appropriate procedures
and warnings as presented in this manual.
Hazardous pressure
can cause personal
injury or property
damage
SCHEDULED MAINTENANCE
STRAINERS
Strainers must be cleaned regularly to avoid pump starvation.
Schedule will depend upon the application and conditions.
LUBRICATION
NOTICE:
To avoid possible entanglement in moving parts do not
lubricate pump bearings, gear reducer or any other parts
while the pump is running.
NOTICE:
If pumps are repainted in the field, ensure that the
grease relief fittings (76A) are functioning properly after
painting. Do NOT paint them closed. Remove any
excess paint from the fittings.
Lubricate pump bearings every three months at a minimum.
More frequent lubrication may be required, depending on the
application and the operating conditions.
Recommended Grease:
Mobil® - Mobilgrease XHP222,
Exxon® - RONNEX MP 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.
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.

107-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.
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 motor adaptor (108)
takes the place of the inboard bearing cover. To
disassemble, take apart the coupling (34) and remove the
mounting screws (28A). The motor adaptor 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). 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, cup the other hand under
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.

107-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) 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).

107-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 motor adaptor (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 motor adaptor takes the
place of the inboard bearing cover (27). To attach the
motor adaptor 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.
Operation without guards in place can
cause serious personal injury, major
property damage, or death.
Do not operate
without guard in
place.
21. Refer to “Pre-Start Up Check List” and “Start Up
Procedures” sections of this manual prior to restarting
pump operation.

107-A00 Page 10/12
TROUBLESHOOTING
NOTICE:
Maintenance shall be performed by qualified technicians only.
Follow 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.

107-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: [e-mail] • Internet Address: www .blackmer.com